Yamaha XS650SE Install guide

XS650E
INDEX
GENERAL
INFORMATION
PERIODIC INSPECTION
AND ADJUSTMENT
ENGINE OVERHAUL
CARBURETION
CHASSIS
ELECTRICAL
I
APPENDICES

XS650SE SUPPLEMENT
(EPA)
XS650E SUPPLEMENT
*XS650SF USES THIS SUPPLEMENT (EPA)
XS650SE SUPPLEMENT
I
XS650SF/2F SUPPLEMENT
XS650G/SG SUPPLEMENT

CHAPTER 1. GENERAL INFORMATION
l-l. MACHINE IDENTIFICATION ...............
a ..........................
.1
l-2. SPECIAL TOOLS ..................................................... .

CHAPTER 1. GENERAL INFORMATION
l-l. MACHINE IDENTIFICATION .
Frame serial number
The frame serial number is stamped on the right side of the steering head stock.
Engine serial number
The engine serial number is stamped on the front of the engine crank case.
NOTE:
The first three digits of these numbers are for model identifications; the remaining digits are the
unit production number.
1-2. SPECIAL TOOLS
1. Cam chain cutter
Parts No. (90890-01112)
c
2. Valve spring compressor
(90890-01253)
,
3. Valve guide reamer
(90890-01211)
J
4.
Valve seat cutter set
5. Piston ring compressors 6. Piston support plate
(90890-01179) (90890-01066) (90890-01067)

I
7. Rotor puller
(90890-01070)
10. Drive chain cutter 11. Pocket tester
(90890-01081) (90890-03096)
13. Vacuum gauge
(90890-03094)
P
8. Clutch holding tool
(90890-01069)
9. Slide hammer
(90890~;z)
12. E lectro tester
(9089@0302 1)
OTHER TOOL PARTS No.
Valve guide remover 90890-01200
Valve guide installer 90890-01201
Spoke wrench
90890-05087
Steering nut wrench
90890-01051
Tappet adjuster wrench .256-28137-00
-2-

CHAPTER 2.
PERIODIC INSPECTION AND ADJUSTMENT
2-1. INTRODUCTION
.....................................................
2-2. MAINTENANCE INTERVAL CHARTS...................................
.4
A. PEPIODIC MAINTENANCE
.........................................
.4
B. LUBRICATION INTERVALS
....
............................... .... 5
2-3. ENGINE
..........................................................
......6
A. Carburetor........................................................ . 6
B.
Air filten ........................................................ .7
C.
Engine/Transmission oil and filter
.....................................
.7
D. Clutch adjustment
..................................................
6
E.
Cam chain adjustment
..............................................
.8
F. Valve clearance adjustment ...........................................
8
G. Crankcase ventilation system
.........................................
.9
H. Exhaust system
....................................................
9
2-4. CHASSIS
..............................................................9
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Fuel petcock cleaning
................................................. 9
Fuel petcock disassembly
............................................
.9
Fuel hose
...........................................................9
Front brake
......................................................
10
Rear brake
.....................................................
..lO
Wheels and tires ................................................... 10
Drivechain
.......................................................
11
Front fork oil change
..............................................
.12
Steering head ..................................................... 12
Lubrication of cables, pivots, etc
......................................
....I3
2-5. ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . 13
A.Contact breaker point adjustment
....................................
.13
B.
Contact breaker point maintenance .....................................
13
C.
lgnition timing .............................................................. 14
D.
Carbon brushes ................................................................ 14
E.
Battery .................................................................... 14
F.
Sparkplug
.......................................................... 15
G.
Headlight .................................................................. 15
-3-

CHAPTER 2.
PERIODIC INSPECTION AND ADJUSTMENT
2-1. INTRODUCTION
This chapter includes all information necessary to perform recommended inspection and adjustments, These
preventive maintenance procedures, if followed, will insure more reliable vehicle operation and a longer service
life. The need for costly overhaul work will be greatly reduced. This information applies not only to vehicles
already in service, but also to new vehicles that are being prepared for sale. Any service technician performing
preparation work should be familiar with this entire chapter.
2-2. MAINTENANCE INTERVALS CHARTS
The following charts should be considered strictly as a guide to general maintenance and lubrication intervals.
You must take into consideration that weather, terrain, geographical location, and a variety of individual uses
all tend to alter this time schedule. For example, if the motorcycle is continually operated in an area of high
humidity, then all parts must be lubricated much more frequently than shown
caused by water to metal parts, on the chart to avoid damage
A.PERIODIC MAINTENANCE
Periodic inspection,adjustment and
lubri-
and most efficient condition.Safety is an ob-
cation will keep your motorcycle in the safest ligation of the motorcycle owner.
Item Remarks
Unit: km (mi
initial Thereafter every
400 800 1,600
3,200
1,600
3,200 6,400
(250) (500) (1,000) (2.000) (1,000) (2.000) (4,000)
Cylinder 1 Check compression I ! IOI I lo
Valves
1 Check/Adjust valve clearance
I I 0101 I lo
Cam chain
( Check/Adjust chain tension
I lo I I I I lo
Spark pluqs
I inspect/Clean or replace as required
loI : lo 1 IO I
Air filter / Dry type - Clean/Replace as required 1
I
:
‘0 II
0 ;
I
Carburetor
| Check operation/Adjust as required
I i 0
’ 0
10 ~
Brake system Check/Adjust as required
- Repair as
(complete) required
i 0 0
/Adjust free play
I
io I
I 0 I I 0 I
Wheel andtires Checkpressure/Wear/Balance 0~ 0 0 ; I 0 I
Fuel petcocks Clean/Flush tank as required 0
0 ~
I
0 I
Battery Top-up/Check specific gravity and 0~breather
pipe 00
1
1 ,o i 0
Ignition timing
| Adjust/Clean or replace parts as required 1 io o/oj
IO I
Lights/Signals / Check operation/Replace as required / 0 ! 0 0
/o/o I
Fittings/Fasteners | Tighten before each trip and/or
lo lo~o/olo/
Generator brushes | Check brush wear/Replace if necessary 1
I ~I I I lo

6. LUBRICATION INTERVALS ,
a_:._ Y- ,-
mission oil
Drive chain
Control/Meter Apply thoroughly
Oil filter element
Wheel bearings
Do not over/ Medium-weight 12,800
Yearly or . . .
wheel bearing grease
(8.000)
Point cam lubri-
cation wicks
Apply very lightly
Light-weight
machine oil
0 0 0 0
-5

2-3. ENGINE
A. Carburetor
1. Idle mixture
The idle mixture is set at the factory by
the use of special equipment. No attempt
should be made to change this adjustment
by the dealer.
1. Do not adjust
2. Throttle
Turn the throttle grip to see if it operates
properly and if the play is normal. Make
certain the throttle snaps closed when
released.
1. 5 - 8 mm (0.2 - 0.3 in)
3. Synchronization
NOTE:
Ignition timing and valve clearances must
be set properly before synchronizing
carburetors.
Procedure:
a. Turn fuel petcocks to “PRIME”, and
remove the plug screws for the adapter
attachment holes in the carburetor body.
b. Install the attachment and set the vacuum
gauge.
c. Start motorcycle and allow it to warm up
for 2
- 3 minutes. The warm-up is com-
plete when engine responds normally to
throttle opening.
d. Adjust damping valve on each vacuum
e.
f.
gauge until the needle flutters only
slightly. The gauge needles must respond
quickly to rapid opening of the throttle.
Both gauge will indicate the same reading
if the carburetors are synchronized.
Turn the synchronizing screw until the
gauge readings are the same.
1. Synchronizing screw
g. After adjustment, firmly tighten the plug
screws.
NOTE:
Check gasket. Replace if damaged.
4. Idle speed adjustment.
NOTE:
Carburetors must be synchronized before
setting final idle speed.
a. Start the engine and warm it up for a few
minutes.
b. Set the engine idle speed to specified rpm
by turning the throttle stop screw in to
increase the engine speed and back off the
screw to decrease the engine speed.
Use a tachometer for checking and adjust-
ing the engine speed.
I
Standard idle rpm:
1,200 rpm
I
-6-

1 .Throttle nap se-
B. Air filters
This model uses a cartridge type air filter
element which consists of foam rubber.
1. Removal
a. Remove the air filter cover by removing
the bolts.
b. Pull out the springs and elements.
2.
a.
Cleaning method
Tap the element lightly to remove most of
the dust and dirt; then blow out the re-
maining dirt with compressed air through
the inner surface of the element. If
element is damaged, replace.
b. Reassemble by reversing the removal pro-
cedure. Check whether the element is
seated completely against the case.
c. The air filter element should be cleaned
once a month or every 1,600
km(l,000
mi.). It should be cleaned more often if
the machine is operated in extremely
dusty areas.
C. Engine/transmission oil and filter
1. Oil level measurement
a. To check the level, warm the engine up
for several minutes. Stop the engine.
With the engine stopped, screw the dip
stick completely out and then rest the
stick in the hole.
1. Oil leuel dip stick
b.
2.
NOTE:
When checking engine oil level with the
dip stick, position the machine straight up
and on main stand.
The dip stick has a minimum and a maxi-
mum mark. The oil level should be
between the two. If the level is low, add
sufficient oil to raise it to the proper level.
Oil replacement and filter cleaning
a. Start the engine. Allow it to warm up for
2-3 minutes. Stop the engine.
b. Place an oil pan under the engine.
c. Remove the drain
plugs and drain the oil.
1. drain plugs
-7

d. Remove the filter cover and oil filter
securing bolt.
HA
1. Filter securing bolt.
e. Slip the filter element out and clean.
f. Install the filter and filter cover.
/
Filter torque:
I 1.0 m-ko f7 f&lb)
g. Reinstall the drain plugs. (Make sure it is
tight.)
/
Drain plug torque:
4.4 m-kg (32 ft-lb)
h. Add oil through the dip stick hole.
r
I
Oil quantity:
2.0 lit (2.1 qt): periodic oil change
2.5 lit (2.6 qt): engine overhauling
Recommended oil:
Yamalube 4-cycle oil or SAE
20W/40 type “SE” motor oil
D. Clutch adjustment
This model has a clutch cable length adjuster
and a clutch mechanism adjuster. Normally,
once the mechanism is properly adjusted, the
only adjustment required is maintenance of
free play at the clutch handle lever.
1. Free play adjustment
Loosen the handle lever adjuster lock nut.
Next, turn the length adjuster either in or
out until proper lever free play is achieved.
2. Mechanism adjustment
a. Screw in the cable adjuster (on the lever
holder) until tight.
b. Screw in the adjuster (push screw) until it
lightly seats against a clutch push rod.
c. Back the adjuster out l/4 turn and
tihgten the lock nut.
d. Adjust the free play of clutch lever by
turning the cable adjuster.
c
1, Adjuster 2. Lock nut
E. Cam chain adjustment
The cam chain becomes stretched with use,
resulting in improper valve timing and engine
noise. To prevent this the cam chain ten-
sioner must be adjusted regularly.
Remove the cap nut.
Turn the adjuster bolt in until the push
rod (inside the adjuster bolt) is flush with
the end of the adjuster bolt.
NOTE:
The push rod will not come out beyond a
certain limit even if the adjuster bolt con-
tinues to be screwed in.
Reinstall the cap nut.
Valve clearance adjustment
NOTE:
Valve clearance must be measured with
the engine at room temperature.
1. 2-3mm (0.08-0.12inl
2. Lock nut
3. Adjuster

1.
2.
3.
4.
Remove all four tappet covers and the
generator cover.
Turn the crankshaft to align the rotor
mark with the “T” mark on the
stator.
This places the pistons at the top dead
center and the valve clearance should be
checked and adjusted at the top dead
center on the compression stroke by
observing when the valve adjusters have
clearance.
Use a feeler gauge to determine the
clearance.
Exhaust valve clearance (cold):
Intake valve clearance (cold):
5. Loosen the valve adjuster lock nut. Turn
the adjuster in or out to obtain the
correct clearance. Hold the adjuster to
prevent it from moving and throughly
tighten the lock nut.
6. Recheck the clearance after tightening.
G. Crankcase ventilation system
1. Check ventilation hose for cracks or
damage.
2. Replace it if necessary.
1, Ventilation hose
2. Fuel pipe
H. Exhaust system
1. Check for leakage from exhaust joints and
retighten joint bolts and nuts.
2.
Replace gaskets if necessary.
2-4. CHASSIS
A. Fuel petcock cleaning
1. Turn the petcock lever to the “ON” or
“RES” position. Remove the fuel pipe.
2. Remove the drain cover and clean it with
solvent.
1 “RES” position
2. Drain cover
B. Fuel petcock disassembly
If the fuel petcock is leaking or excessively
contaminated, it should be removed from the
fuel tank and inspected.
1.
2.
3.
4.
5.
Remove fuel tank and position it so that
fuel will not spill when the petcock is
removed.
Remove petcock and inspect filter screen.
Clean or replace filter if seriously con-
taminated.
Remove screws on front and rear of pet-
cock and remove plate, gaskets, lever and
diaphragm.
Inspect all components and replace any
that are damaged. If the diaphragm is in
any way damaged, or the petcock body
gasket surfaces scratched or corroded, the
petcock assembly must be replaced. If
there is abrasive damage to any com-
ponent, the fuel tank must be drained and
flushed.
Reassemble petcock and install on fuel
tank.
C. Fuel hose
1. Check fuel hose for cracks or damage.
2. Replace it if necessary.
- 9 -

D. Front brake
The brake can be adjusted by simplay adjust-
ing the distance that the brake lever can
travel. (The piston in the caliper moves for-
ward as the brake pad wears out, automati-
cally adjusting the clearance between the
brake pad and the brake disc.)
1.
a.
Adjustment
Turn adjuster so that a brake lever end is
5
- 8 mm (0.2 - 0.3 in) before adjuster
contacts master cylinder piston.
1. 5-8mmI0.2-0.3inl
2. Lock nut
3. Adjuster
2. Brake pad check
1, Indicator cap
To check, open the wear indicator cap
and if any pad is worn to the red line, re-
place pads.
3. Check the brake fluid level
Insufficient brake fluid may allow air to
enter the brake system, possibly causing
the brake to become ineffective. Check
the brake fluid level and replenish when
necessary and observe these precautions:
a. Use only the designated quality brake
fluid; otherwise, the rubber seals may de-
teriorate, causing leakage and poor brake
performance.
Refill with the same type and brand of
brake fluid; mixing fluids may result in a
harmful chemical reaction and lead to
poor performance.
Be careful that water or other contamina-
tion does not enter the master cylinder
when refilling. Water will significantly
lower the boiling point and may result in
vapor lock.
E. Rear brake
1. Adjust rear brake pedal play to suit, pro-
viding a minimum of 20
- 30 mm (0.8 -
1.2 in) freeplay. Turn the adjuster on the
rear brake rod in or out until brake pedal
free play is suitable.
NOTE:
Rear brake pedal adjustment must be
checked anytime chain is adjusted or rear
wheel is removed and then reinstalled.
1. Adjuster
F. Wheels and tires
1.
a.
2.
a.
Recommended brake fluid:
DOT No. 3 Brake fluid
Wheels
Check each spoke for tightness.
NOTE:
If loose spokes are found, tighten and
repeat rim
runout check.
Tires
Important notice
Proper loading of XS650E is important
for the handling, braking, and other
performance and safety characteristics.
NEVER OVERLOAD THE MOTOR-
CYCLE.
WARNING: Never overload the motor-
cycle beyond specified tire limits. Opera-

FRONT REAR
XS650E BASIC
WEIGHT
with oil
104 kg@29 lb) 119 kg1262 lb)
md full fuel tank
Standard tire
Bridgestone or Bridgestone or
Yokohama Yokohama
3.50H19-4PR 4.OOHlB-lPR
Tire load limit
234 kg (515 lb) 280 kg (615 lb]
Cold tire pressure
Normal riding 1.6 kg/cm’
2.0 kg/cm2
(22 psi)
(28 psi)
With passenger 2.0 kg/cm2 2.3 kg/cm’
or high speed
riding (28 psi) (32
psi)
With passenger 2.8 kg/cm2
2.8 kg/cm2
$$xtra load
(40 psi) (40 psi)
Vlinimum tire 0.8 mm 0.8 mm
:read depth (0.03 in)
(0.03 in)
Make sure the total weight of the motorcycle with
accessories,
rider(s) etc., does not exceed the tire
limits.
b. Check the tire wear
If a tire tread shows cross wise lines, it
means that the tire is worn to its limit.
Replace the tire.
c. Check the wheel damage and check the
tightness of spokes.
G. Drive chain
1. Tension check
a. Inspect the drive chain with mainstand
erected. Check the tension at the position
shown in the illustration. The normal ver-
tical deflection is approximately 20 mm
(3/4 in).
20 mm (3/4 in)
2. Tension adjustment
a. Loosen the rear brake adjuster.
b. Remove the cotter pin of the rear wheel
axle nut.
c. Loosen the rear wheel axle nut.
d.
Loosen the adjuster lock nuts on each
side.
e. To tighten chain turn chain puller ad-
juster clockwise.
Turn each bolt exactly the same amount
to maintain correct axle alignment.
There are marks on each side of rear arm
and on each chain puller; use them to
check for proper alignment.
1. Alignment marks
2. Rear axle nut
3. Adjuster
4. Lock nut
5. Cotter pin
f. After adjusting be sure to tighten the lock
nuts and the rear wheel axle nut.
g. Install a new cotter pin and bend the end
over.
h. In the final step, adjust the play in the
3.
a.
brake pedal and stoplight switch free play.
Lubrication
First, remove dirt and mud from the chain
with a brush or cloth and then spray the
lubricant between both rows of side plates
and on all center rollers.
-,I -

b. To clean the entire chain, first remove
the chain from the motorcycle, dip it in
solvent and clean with stiff brush. Then
take the chain out of the solvent and dry
it. Immediately, lubricate the chain to
prevent the formation of rust.
H. Front fork oil change
1. Raise the front wheel off the floor with a
suitable frame stand.
2. Loosen the fork pinch bolts.
3. Remove the rubber cap from the top of
each fork.
1. Pinch bolt 2. CSP
4. Loosen the cap bolt (adjuster unit).
5. Remove drain screw from each outer tube
with open
container under each drain hole.
1. DreainScrew
rCAUTION:
Do not allow oil to contact disc brake
components.
6. After most oil has drained, slowly raise
and lower outer tubes to pump out re
maining oil.
7. Install drain screw.
NOTE:
Check gasket. Replace if damaged.
8. Pour specified amount of oil into the in-
ner tube through the upper end opening.
Front fork oil:
Yamaha fork oil 10 Wt
I
Front fork oil capacity:
164
- 172 cc (5.54 - 5.82 oz)
each side
9.
After filling, slowly pump the outer tubes
up and down to distribute the oil.
10. Inspect O-ring on fork cap bolts and re-
place if damaged.
6
1. O-ring
11. Install fork cap bolts.
12. Tighten pinch bolts.
I
Tightening torque:
m-kg
ft-lb
I
Fork cap bolt
Pinch bolt
5.0
36
1.0
7
I. Steering head
1.
adjustment
The steering assembly should be checked
periodically for looseness.
Do this as follows:
a.
Raise front end of machine so that there
is no weight on the front wheel.
b. Grasp bottom of forks and gently rock
fork assembly backward and forward,
checking for looseness in the steering
assembly bearings.
- I2 -

the end of the cable can be held high to
pour in several drops of lubricant. With
throttle grip disassembled, coat the inside
surface of the throttle grip guide tube
with a suitable all-purpose grease to cut
down friction.
2. Meter cables
Pull the inner cable out and apply cable
lube throughly.
c. If there is looseness in the steering head,
loosen the crown pinch bolt, fork pinch
bolts, and steering fitting bolt.
1. Crown pinch bolt
2. Fork pinch bolt
3. Steering fitting bolt
d.
e.
f.
g.
2.
Use steering nut wrench to loosen top
steering fitting nut. The top nut serves as
a lock nut.
Tighten the lower steering fitting nut until
the steering head is tight, but does not
bind when forks are turned.
Retighten the top steering fitting bolt,
crown pinch bolts and fork pinch bolts, in
that order.
Recheck steering adjustment to make sure
there is no binding when the forks are
moved from lock to lock. If necessary,
repeat adjustment procedure.
Lubrication
Refer to PAGE 47.
J. Lubrication of cables, pivots, etc.
1. Throttle cable and grip
The throttle twist grip assembly should be
greased at the time that the cable is lubri-
cated since the grip must be removed to
get at the end of the throttle cable. Two
screws clamp the throttle housing to the
handlebar. Once these two are removed,
3. Rear arm pivot shaft
Apply grease to grease nipple on top of
pivot with low pressure hand operated
gun. Apply until fresh grease appears at
both ends of pivot shaft.
Recommended lube:
Medium-weight wheel bearing grease
4. Brake and change pedal shafts, and center
and side stand pivots Lubricate the shafts
and pivots with Yamaha chain and cable
lube or SAE
l0W/30 motor oil.
5. Wheel bearings
Refer to PAGE 39.
2-5. ELECTRICAL
A. Contact breaker point adjustment
1.
2.
3.
Remove breaker point cover.
Check contact breaker point gap (at
largest gap) with clean feeler gauge.
Contact breaker gap:
0.3 - 0.4 mm (0.012 - 0.016 in)
If necessary, adjust by loosening securing
screws and moving the adjustable contact
point.
Tighten adjusting screws and recheck
breaker point gap.
B. Contact breaker point maintenance
1. The contact breaker should be checked
for the following:
a. Wear of the bakelite cam heel
b. Damage of contact point surfaces
-13-

c. Rust or wear on the breaker arm or arm
shaft.
d. Faulty insulation of the contact braker
e
2.
3.
4.
assembly.
Oil or dirt on the assembly.
To clean the points, run a point file be-
tween the points until the grey deposits
and pits have been removed. Spray the
points with ignition point cleaner or
lacquer thinner, then snap the points shut
on a white business card (or paper of hard
texture) and repeatedly pull the card
through until no more carbon or metal
particles come off on the card. (The card
may be dipped in lacquer thinner or other
cleaner to facilitate this procedure.)
Point replacement should be necessary
when the points become severely pitted, if
the heel is broken or worn unevenly, or if
the points become shorted or show faulty
operation.
NOTE:
New points must be cleaned and adjusted.
Add a few drops of light-weight machine
oil onto the felt rubbing pad after each
point adjustment to lubricate the point
cam surface. Do not over oil.
C. Ignition timing
NOTE:
Point gap must be set before setting timing.
1. Ignition timing is checked with a timing
light by observing the position of the
stationary marks stamped on the
stator
and the pointer on the generator.
1. Top dead center
2.
15’ BT0C11.200 rpm
3. Advanced mark
_
2.
3.
4.
5.
6.
7.
Ignition timing of right-hand cylinder
must be set first. Connect timing light to
right-hand spark plug lead wire.
Start engine.
The mark stamped on the rotor_ should
line up with the stationary “F” timing
mark. If it does not align, loosen two
breaker backing plate screws and move
the complete backing plate until the mark
on the rotor and the “F” mark align.
Retighten screws. Check timing again for
the right-hand cylinder.
Rev the engine to above 3,500 rpm.
Check whether the mark on the rotor is in
the vicinity of the stationary “full ad-
vance” mark.
Repeat procedure (steps 2-6) for another
cylinder.
1. Rlghf cylinder timing adfustment
2. Left cylinder timmg adjustment
D. Carbon brushes
Visually inspect the carbon brush holder
brushes for obvious breakage or wear.
Standard brush length is 14.5 mm(0.571 in).
Wear limit is 7.0 mm (0.276 in) and
marked there.
E. Battery
A poorly maintained battery will deteriorate
quickly. The battery fluid should be checked
at least once a month.
1. The level should be between the upper
and lower level marks. Use only distilled
water for refilling. Normal tap water con-
tains minerals which are harmful to a
battery; therefore, refill only with dis-
tilled water.
2. Always make sure the connections are
correct when installing the battery. The
magnet relay lead is for the
(+) terminal
14 -

and thechassis lead is for the (-) terminal.
Make sure the breather pipe is properly
connected, properly routed, and is not
damaged or obstructed.
NOTE:
The battery must be charged before using
to insure maximum performance. Failure
to properly charge the battery before first
use, or a low electrolyte level, will cause
premature failure of the battery.
Charging current: 1.4 Amp
Charging hours: 10 hrs
F. Spark plug
The spark plug indicates how the engine is
operating. If the engine is operating correctly,
and the machine is being ridden properly, the
tip of the white insulator around the positive
electrode of the spark plug will be
a medium
tan color. If the insulator is very dark brown
1. If the insulator is very dark brown or
black color, then a plug with a hotter heat
range might be required. This situation is
quite common during the engine break-in
period.
2. If the insulator tip shows a very light tan
or white color or is actually pure white
and glazed, or if electrodes show signs of
melting, then a
spark plug with a colder
heat range is required. Remember, the
insulator area surrounding the positive
electrode of the spark plug must be a
medium tan color. If it is not, check
carburetion, timing and ignition adjust-
ments.
3. The spark plug must be removed and
checked. Check electrode wear, insulator
color, and electrode gap.
Spark plug gap:
0.7
- 0.8 mm (0.028 - 0.031 in)
Engine heat and combustion chamber de-
posits will cause any spark plug to slowly
break down and erode. If the electrodes
finally become too worn, or if for any reason
you believe the spark plug is not functioning
correctly, replace it. When installing the plug,
always clean the gasket surface, use a new
sent on the surface of the spark plug, and
torque the spark plug properly.
Standard spark plug:
Champion N-7Y or NGK
BP 7ES
Tightening torque:
2.0 m-kg (14 ft-lb)
G. Headlight
1. Headlight beam adjustment.
When necessary, adjust the headlight
beam as follows:
a. Adjust horizontally by tightening or
loosening the adjust screw.
To adjust to the right:
Tighten the screw
To adjust to the left:
Loosen the screw
b. Adjust vertically as follows:
1)
Loosen adjusting screw and adjust ver-
tically by moving the headlight body.
2)
Retighten the screw.
1. Vertical adjustment
2. Horizontal adjustment
2. Replacing the headlight bulb.
_-_._
_ --
a. Loosen bolts and replace bulb.
b. After installing, adjust headlight beam.
NOTE:
Take care not to damage the headlight. It
gasket, wipe off any grime that might be
pre-
- 15 -
is very fragile.

3-1.
3-2.
3-3.
CHAPTER 3. ENGINE OVERHAUL
ENGINE REMOVAL
........................................
A. Preparation for removal
...................................
B. Fuel tank removal
.......................................
C. Removal of other parts.
...................................
D. Engine mounting bolts and engine removal
....................
ENGINE DISASSEMBLY
....................................
A.
Governor and breaker assembly removal
........
B.
Cylinder head and cylinder removal
............
C.
Rocker arm removal
........................
D.Valve removal
.............................
E.
Piston removal
............................
F.
Generator removal
.........................
G.
Primary drive gear and clutch assembly removal
...
H. Kick axle and change shaft removal
............
I.
Electric starter unit removal
..................
J.
Oil pump removal.
.........................
K.Crankcase disassembly
......................
L.
Transmission illustration
....................
M.Shift drum removal
........................
N.Crank shaft removal
........................
....
.18
....
.18
.... .18
....
.I8
....
.18
..... .19
.....................
19
.....................
19
.....................
19
..................... 19
..................... 19
..................... 19
.....................
19
.................... .20
.....................
20
.....................
20
.....................
20
.....................
21
.....................
21
.....................
22
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
0.
P.
Q.
R.
Cyinder head cover.
...............................................
.22
Cylinderhead.....................................................2 2
Valve, valve guide and valve seat.
.....................................
.23
Valvespring......................................................2 4
Rocker arm and rocker shaft
........................................
.25
Cam shaft wear ..................................................2 5
Cam chain, sprocket and dampers
....................................
.26
Cylinder.........................................................2 6
Piston and rings
..................................................
.26
Pistonpin........................................................2 7
Crankshaft ..................................................... ..2 7
Oil pumpp ...................................................... ..2 7
Clutch ........................................................ ..2 8
Transmission .....................................................2 8
Electric starter gears and clip spring
...................................
.29
Kickstarter......................................................2 9
Crankcase and oil passages
..........................................
.29
Bearings and oil seals
...............................................
29