Archive for the ‘Manual – Workshop’ Category

XS650: Troubleshooting Manual   Leave a comment

If you have ended here and not where you want to go – VOU HAVE A VIRUS ON YOUR COMPUTER … do us both a favour and scroll back to my blog post Virus. Please read this then do a search as suggested.

Yamaha Troubleshooting Manual

In 3 languages. English. French. German

Troubleshooting Manual

Yamaha Troubleshooting Manual

Trouble Shooting

– hopefully this can prove organic … comments and suggestions – correcting, extending
– an engine is basically an air pump – 4 stroke …  suck, squeeze, bang, blow
– add fuel, timing and spark = internal combustion engine
– break this system anywhere and you wont get much action

– so your engine turns over ? wont start
– what have you done ? what have you changed, altered, played with, unfixed ?
– air ? fuel ? spark ? …all in the correct ammount and moment ?
– don’t panic…turn the key and petcock/s off, step back …take a breath-deep, go do something you really enjoy for a couple of minutes…

  •  fuses ? kill switch ?
  •  battery ? 12.6 V ? put it on charge, brushes ? check charging system
  • power to coil/s ? points spark ? plugs ?
  • filters ?
  • fuel to carbs ? bowls ? cylinders ? floods ?
  • compression ? leak-down test ?

·

  •    adjust your cam chain … can readjust warm once you get her running
  •       set your tappets
  •       set your points if you have them .. plugs

 

– once you get this far she should be at least spitting and farting enough to attempt setting your carbs …

  • if she wont idle, look for air leaks ? atu ? massage her pilot jet circuits
  • once you can get idle, do the idle speed screw/pilot air screw dance
  • smooth transition through to full throttle ?
  • synchronise

Electric Troubleshooting

Carburetor Troubleshooting

Starting System Troubleshooting

Engine Troubleshooting

Oil Troubleshooting

Clutch and Gearbox Troubleshooting

Frame Troubleshooting

XS650: Parts Failure   Leave a comment

Found this publication while rummaging around in my boxes of shit. I love these boxes. You never really know just what you will find. Auctions and fleamarkets rule!

Parts Failure ID Guide

 

parts failure id guide

table of content

 

 

Parts Failure ID Guide

Note:

  • ”Includes explanations and possible reasons for failure…
  • These failures are not necessarily the only conditions that could cause the failure…
  • Make sure to consider all factors concerning the operation and maintenance of the machine when analysing failures…
  • Most of the shown failures are secondary…
  • Some other problem may have caused them…
  • Be sure to find the original problem area during diagnosis…
  • Not all causes are identified here”

If following the above link, look for the 7 sub-albums to the right.

XS650: XS1 XS2 TX650 TX650A Service Manual 1970-1974   Leave a comment

XS1 – XS1B – XS2 – TX650 – TX650A Manual 1970-74

 

Yamaha Service Manual 1970 – 1974, pages 0-50

Introduction……………………………………………………………………………..1

Chapter 1: Engine

  • A: Removing Engine from Frame…………………………………………10
  • B: Installing Engine in Frame………………………………………………13
  • C: Engine Disassembly Notes………………………………………………13
  • D: Cylinder Head Cover (Disassembly)………………………………..14
  • E: Cylinder Head……………………………………………………………….20
  • F: Cylinder and Piston Assembly…………………………………………33
  • G: Primary Case………………………………………………………………..41

Yamaha Service Manual 1970 – 1974, pages 51-100

  • H: Alternator Case Cover………………………………………………….51
  • I: Crankcases…………………………………………………………………..53
  • J: Service Checks/Adjustments………………………………………..64

Chapter 2: Fuel System

  • A: Petcock………………………………………………………………………..66
  • B: Carburetor…………………………………………………………………..66
  • C: Air Filter………………………………………………………………………78

Chapter 3: Frame

  • A: Seat Removal……………………………………………………………….79
  • B: Voltage Regulator Removal……………………………………………79
  • C: Battery Box Removal……………………………………………………79
  • D: Secondary Ignition Coil Removal……………………………………79
  • E: Front Forks…………………………………………………………………81
  • F: Rear Suspension………………………………………………………….86
  • G: Wheels……………………………………………………………………….87
  • H: Front Wheel………………………………………………………………..91
  • I: Rear Wheel………………………………………………………………….94
  • J: Drive Chain………………………………………………………………….97

Chapter 4: Electrical

  • A: Battery……………………………………………………………………….99

Yamaha Service Manual 1970 – 1974, pages 101-150

  • B: Main Switch……………………………………………………………….101
  • C: Charging Circuit…………………………………………………………102
  • D: Ignition Breaker Points………………………………………………110
  • E: Advance Assembly……………………………………………………..112
  • F: Condensor………………………………………………………………….113
  • G: Ignition Coil……………………………………………………………….114
  • H: Spark Plug…………………………………………………………………114
  • I: Setting Ignition Timing………………………………………………..115
  • J: Lighting Circuit……………………………………………………………117

XS2 TX650 Supplement………………………………………………….120

Yamaha Service Manual 1970 – 1974, pages 151-188

XS2 TX650 Supplement……………………………………………………151

TX650 Parts Supplement…………………………………………………153

TX650A Supplement…………………………………………………………158

Appendices

  • A: Cleaning and Storage…………………………………………………….171
  • B: Troubleshooting……………………………………………………………173
  • C: XS Series Pertinent Parts and Service Bulletins……………….176

When I converted this to pdf’s I didn’t pay attention to the page divisions. I will do it again at some stage in separate chapters.

Posted January 14, 2012 by xscafe in Manual - Workshop

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XS650: Model, Year, Model code, Engine Number   Leave a comment

I made this list up some years ago. This version is arranged in Model Code numeric sequence. This code is found on the steering stem ID/VIN plate and Registration Papers. This is not necessarily the same as the first 3 places of the Engine Number.

MODEL       YEAR       MODEL CODE          ENGINE NUMBER

XS-B            75-76                 533                        447-500101

I’m sure it’s not complete. May include errors. If you have a machine with a model code not listed here let me know.

 

… by model code – page 01

 

… model codes – page 02

 

Or here listed by Engine Number.

… by engine number – page 01

 

by engine number – page 02

 

As you can see, there are questions. (???)

… my original tables included these model code/engine number combinations … they are not however confirmed by Yamaha … if you have a machine covered by one of these please let me know and I will reinclude it in the above tables

 

Have a Model Code that’s not listed here? Let me know.

I wish to get an idea of production runs. The engine numbers in the above tables are arranged so … 447-300101 to (400000). I have the start number for each model. Yamaha have given the absolute end number-these are in brackets. Not necessarily the real end number. Where I know this I have entered it without brackets … 2F0-000101 to 006141. The information is from Yamaha Publication #12100-100E1.

I’m looking for approximate end numbers. If you want you could leave me your model and engine number. No Name. No address. When left in the comment box below no one will see it.

XS650: Shell Service Guide   Leave a comment

Shell Marketing getting in on the action. 11/75.

 

shell service guide

 

XS500 … XS650

 

XS650 shell service guide

XS650: XS650SJ Service Manual   Leave a comment

Link to more manuals.

XS650SJ/SK manual

 

XS650SJ Manual Chapter 1

  • General Information

XS650SJ Manual Chapter 2  Periodic Inspection

  • Intro
  • Engine
  • Chassis
  • Electrical

XS650SJ Manual Chapter 3  Engine Overhaul

  • Removal
  • Disassembly
  • Inspection and Repair
  • Assembly and Adjustment

XS650SJ Manual Chapter 4  Carburetion

XS650SJ Manual Chapter 5  Chassis

  • Front Wheel
  • Rear Wheel
  • Front Brake
  • Front Fork
  • Steering Head
  • Swing Arm
  • Cables and Fitting

XS650SJ Manual Chapter 6  Electrical

  • Starter
  • Charging
  • Ignition
  • Lighting
  • Signals

XS650SJ Manual Chapter 7  Appendices

Posted April 26, 2011 by xscafe in Manual - Workshop

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XS650: Other Manuals   Leave a comment

Got a lot of use out of these too…

SRX6 Workshop Manual

SRX600 Owners manual

Yamaha_XS360_400_Service_manual

Yamaha XT500 SR500 Service Manual

Posted April 20, 2011 by xscafe in Manual - Workshop

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