Yamaha XS650H XS650SH 1981 Workshop Repair Service Manual

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Type: Motorcycle

Vendor:

Sku: 75958

Tags: 1981 Misc Motorcycle Motorcycles XS650H XS650SH Yamaha

Product variants

Description

The Yamaha XS650 Special, including the XS650H and XS650SH variants from 1981, represents a significant chapter in Japanese motorcycle design. These models are celebrated for their iconic air-cooled, four-stroke, parallel-twin engines, delivering robust performance and a distinctive character that appealed to riders seeking a classic cruising experience or a foundation for personalization. Known for their robust construction and enduring appeal, the XS650 Special motorcycles have become a favorite in the custom motorcycle community, appreciated for their timeless styling and the potential for unique modifications. This comprehensive Workshop Repair Service Manual provides essential information for the maintenance and repair of your Yamaha XS650 Special. Covering a wide range of systems including the engine, fuel, ignition, transmission, electrical, brakes, and suspension, this manual details everything from routine maintenance procedures like oil changes and adjustments to complete component overhauls and troubleshooting guides. It is designed to assist owners, mechanics, and technicians in keeping their motorcycles in optimal condition, ensuring reliability and performance through clear, step-by-step instructions and vital technical specifications.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XS650 Special

Model Variant:

XS650H, XS650SH

Year:

Codes

Chassis Code H:

XS650H

Chassis Code Sh:

XS650SH

👋 Introduction

Market Position

Description:

The Yamaha XS650 series, particularly the Special models, were popular Japanese custom-style motorcycles of their era, known for their torquey parallel-twin engines and classic styling, appealing to riders seeking a more relaxed cruising experience or a platform for customization.

Competitive Analysis

Competitors:

Competed with other Japanese cruisers and standard motorcycles of the late 70s and early 80s, as well as American V-twin offerings. Its parallel-twin configuration offered a distinct character compared to the V-twins.

Key Features

Features:

Iconic parallel-twin engine, distinctive styling, robust construction, and a strong aftermarket support base contributing to its custom potential.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and overhaul of Yamaha XS650H and XS650SH models

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine assembly, disassembly, tuning, and troubleshooting

Fuel System:

Carburetor adjustment, cleaning, and repair; fuel tank, lines, and petcock service

Ignition System:

Ignition timing, coil testing, spark plug service, and points adjustment

Transmission Drivetrain:

Clutch operation, gearbox disassembly and assembly, final drive maintenance

Electrical System:

Wiring diagrams, lighting system, battery charging, starter motor, and instrument panel service

Brakes:

Front and rear brake system maintenance, adjustment, and component replacement

Suspension Steering:

Front fork service, rear shock absorber maintenance, steering head bearing adjustment

Wheels Tires:

Wheel bearing maintenance, tire replacement, and spoke tensioning

Frame Bodywork:

Frame inspection, seat and tank removal/installation, minor bodywork adjustments

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, lubrication points, chain adjustment

Troubleshooting:

Diagnostic charts for common problems and their solutions

Component Overhaul:

Detailed instructions for rebuilding major components like the engine and transmission

Adjustments:

Carburetor synchronization, ignition timing, clutch cable, brake levers

Torque Specifications:

Essential torque values for critical fasteners

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine rebuilds and advanced diagnostics

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality Description:

High-resolution scans suitable for digital viewing and printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchability:

Likely text-searchable PDF (depending on original scan quality)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, SOHC, parallel-twin

Displacement:

653 cc (39.8 cu in)

Bore X Stroke:

75 mm x 74 mm (2.95 in x 2.91 in)

Compression Ratio:

8.4:1

Valve Arrangement:

SOHC, 2 valves per cylinder

Performance

Horsepower Approx:

53 hp @ 6,500 rpm (est.)

Torque Approx:

52 lb-ft @ 5,000 rpm (est.)

Fuel System

Carburetor Type:

Dual Mikuni VM34SS

Fuel Capacity:

13.0 L (3.4 US gal)

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition) with dual spark plugs per cylinder

Lubrication

Oil Capacity With Filter:

Approx. 2.5 L (2.6 US qt)

Recommended Oil Viscosity:

10W-40 or 20W-50 (refer to manual for specific climate recommendations)

Engine Mounts

Engine Mounting:

Rubber-mounted for vibration isolation

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

Features

Gear Ratios:

Specific ratios detailed within the manual

Transmission Oil Type:

Yamalube 20W-40 or equivalent motorcycle-specific transmission oil

📐 Dimensions

Exterior

Length:

Approx. 2220 mm (87.4 in)

Width:

Approx. 830 mm (32.7 in)

Height:

Approx. 1160 mm (45.7 in)

Wheelbase:

Approx. 1460 mm (57.5 in)

Weights

Dry Weight:

Approx. 193 kg (425 lbs)

Wet Weight:

Approx. 208 kg (458 lbs) (est.)

Cargo

Cargo Capacity:

N/A (Motorcycle)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable in modern automotive crash test rating systems

Active Features

Brakes Front:

Single Disc Brake

Brakes Rear:

Drum Brake

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals

Instrumentation:

Speedometer, tachometer, neutral indicator, high beam indicator, turn signal indicators

💡 Technology Features

Infotainment

Infotainment System:

N/A (Analog instrumentation)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

Engine Management

Engine Management System:

Mechanical carburetor and CDI ignition, requiring manual tuning and adjustment.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months (refer to manual for precise recommendations)

Air Filter Cleaning:

As needed, or every 6,000 km (3,600 miles)

Spark Plug Replacement:

Every 12,000 km (7,200 miles) or as per inspection

Valve Clearance Check:

Every 6,000 km (3,600 miles)

Clutch Adjustment:

As needed

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/rain

Fluid Specifications

Engine Oil Type:

API SE, SF or SG classified, SAE 10W-40 or 20W-50 motorcycle oil

Brake Fluid Type:

DOT 3 or DOT 4 (for disc brake system)

Known Issues

Common Wear Items:

Cam chain wear, output shaft seal leaks, carburetors requiring synchronization, charging system components (rectifier/regulator), and valve guide wear over high mileage.

Typical Repairs:

Piston ring replacement, top-end rebuilds, clutch adjustments and replacements, carburetor rebuilds.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Corporation, founded in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various disciplines.

Model Evolution

Xs650 Lineage:

The XS650 series was introduced in 1970 and was a significant model for Yamaha, evolving through various iterations and special editions. The 1981 models represent a mature stage of this popular platform.

Production

Production Period:

1970-1983 for the XS650 line

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Classic Status:

Considered a modern classic by many enthusiasts, appreciated for its enduring design and mechanical character.

Ratings

Enthusiast Appreciation:

Highly regarded in the custom motorcycle community for its suitability as a build platform.