🏷️ Basic Information

Make:

Yamaha

Model:

XS650H / XS650SH

Year:

1981

Type:

Motorcycle

Chassis Code Xs650H:

2H7

Chassis Code Xs650Sh:

3X1

👋 Introduction

Era:

Late 70s / Early 80s Classic Japanese Motorcycle Segment

Target Audience:

Enthusiasts, Restorers, DIY Mechanics, Owners of the Yamaha XS650 series

Competitors:

Triumph Bonneville, Moto Guzzi V7, Kawasaki KZ650, Honda CB750F

Key Selling Points Vehicle:

Torquey parallel-twin engine, distinctive styling, robust build quality, strong aftermarket support.

Manual Value Proposition:

Provides in-depth, factory-authorized information for maintaining, troubleshooting, and repairing the Yamaha XS650H/SH, crucial for preserving its value and performance.

Manual Benefits:

Empowers owners to perform complex maintenance and repairs, reducing reliance on costly dealer services and enhancing understanding of the machine.

📋 Manual Details

Engine:

Full Engine Overhaul, Carburetor Tuning, Ignition System

Transmission:

Gearbox Disassembly/Reassembly, Clutch Operation, Final Drive

Chassis:

Frame, Suspension (Front & Rear), Steering, Wheels, Tires

Electrical:

Wiring Diagrams, Lighting, Ignition, Charging System, Battery

Brakes:

Front & Rear Brake Systems (Hydraulic & Mechanical), Disc & Drum

Bodywork:

Fuel Tank, Seat, Fenders, Handlebars, Controls

Troubleshooting:

Diagnostic Procedures, Common Faults & Solutions

Estimated Pages:

Hundreds of pages (exact number not specified but indicative of comprehensive coverage)

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Systems:

2X 650cc Parallel-Twin, Air-Cooled, SOHC, 4-Stroke; Carburetor Systems (Mikuni VM34); Ignition (CDI); Lubrication System; Cooling System (Air); Valve Train

Transmission Systems:

5-Speed Constant Mesh Sequential Gearbox; Multi-Plate Wet Clutch; Chain Drive Final Drive

Chassis Systems:

Steel Tube Double Cradle Frame; Telescopic Front Forks (35mm stanchions); Rear Swingarm with Dual Shock Absorbers; Spoked Wheels; Drum & Disc Brakes

Electrical Systems:

12V Electrical System; Alternator; Battery (YB10L-A2); Headlight, Taillight, Turn Signals; Ignition Coil; Starter Motor; Instruments (Speedometer, Tachometer, Indicators)

Routine Maintenance:

Oil Changes, Filter Replacement, Chain Lubrication & Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Brake Adjustment, Tire Pressure Checks

Engine Repair:

Top End Rebuild (Cylinder Head, Piston, Rings); Bottom End Rebuild (Crankshaft, Bearings, Seals); Camshaft Removal/Installation; Carburetor Rebuild & Synchronization; Valve Adjustment

Transmission Repair:

Gearbox Disassembly, Reassembly, Bearing Replacement; Clutch Assembly Inspection, Replacement

Electrical Diagnostics:

Wiring Diagram Interpretation, Troubleshooting Electrical Faults, Charging System Testing, Ignition Timing Verification

Brake Service:

Brake Pad/Shoe Replacement, Disc/Drum Inspection, Hydraulic System Bleeding, Caliper/Cylinder Overhaul

Suspension Service:

Fork Seal Replacement, Fork Oil Change, Rear Shock Absorber Servicing/Replacement

Troubleshooting Guides:

Step-by-step diagnostic flowcharts for common problems (e.g., starting issues, poor performance, electrical failures)

Depth:

Comprehensive: Covers routine maintenance, intermediate repairs, and complete engine/chassis overhauls. Suitable for experienced DIY mechanics and professional technicians.

Diagnostic Capability:

High: Includes detailed troubleshooting sections with specific symptom-to-cause mappings and repair procedures.

Rebuild Capability:

Full: Provides instructions for complete disassembly and reassembly of major mechanical and electrical components.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Quality:

High Resolution, Scan Quality (assumed for factory manual, enables clear printing)

Digital:

N/A (Digital Download)

Digital:

N/A (Digital Download - printable pages)

Text Search:

Searchable Text (standard for most factory PDF manuals)

Hyperlinks:

Likely includes internal hyperlinks for navigation (common in modern PDFs)

⚙️ Engine Specifications

Engine Type:

Parallel-twin, Four-stroke, Air-cooled, OHC

Displacement:

653 cc

Bore X Stroke:

75 mm x 74 mm

Compression Ratio:

8.8:1

Valve Actuation:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Horsepower:

Approx. 50 HP @ 6200 RPM (at crankshaft, for H/SH models)

Torque:

Approx. 59 Nm (43.5 lb-ft) @ 4500 RPM

Carburetors:

2 x Mikuni VM34-12 (or similar BST type on later models - manual will cover specifics)

Fuel Type:

Unleaded gasoline (minimum 91 octane recommended for modern fuel compatibility)

Type:

CDI (Capacitor Discharge Ignition) with Electronic Advance

Type:

Wet Sump

Oil Capacity:

Approx. 2.7 Liters (with filter change)

Recommended Oil:

Yamalube 4-stroke motorcycle oil, or equivalent SAE 20W-40 or 10W-40 (API SG or higher)

🔧 Transmission

Type:

5-speed constant mesh sequential transmission

Gear Ratios:

Details available in manual (e.g., 1st: 2.833, 2nd: 1.800, 3rd: 1.310, 4th: 1.050, 5th: 0.875 - typical ratios)

Type:

Wet, multi-plate

Actuation:

Cable-operated, handlebar lever

Type:

Chain drive

Gear Ratio Final:

Typical 3.000 (e.g., 36/12 tooth sprockets)

Transmission Oil Type:

Yamalube SAE 80W motorcycle gear oil, or equivalent API GL-4

📐 Dimensions

Overall Length:

Approx. 2,220 mm (87.4 in)

Overall Width:

Approx. 800 mm (31.5 in)

Overall Height:

Approx. 1,230 mm (48.4 in)

Wheelbase:

Approx. 1,465 mm (57.7 in)

Dry Weight:

Approx. 190 kg (419 lbs)

Wet Weight:

Approx. 207 kg (456 lbs) (fully fueled, ready to ride)

Gross Vehicle Weight Rating:

Not typically specified for motorcycles, but refer to manual for load limits.

Front Tire:

3.50-18 4PR

Rear Tire:

4.00-18 4PR

Wheelbase Type:

Spoked wheels, 18-inch diameter front and rear

Fuel Tank Capacity:

Approx. 16 Liters (4.2 US gal)

🛡️ Safety Features

Crash Safety:

N/A (Motorcycle safety ratings are not standardized like automobiles; focus is on handling and rider protection, detailed in manual).

Braking System:

Front: Hydraulic Disc Brake; Rear: Mechanical Drum Brake (specifics vary by region/trim, manual covers both).

Suspension Stability:

Well-tuned suspension system designed for stability and predictable handling.

Lighting:

Headlight, Taillight, Brake Light, Turn Signals for visibility.

Ergonomics:

Riding position designed for comfort and control.

💡 Technology Features

System:

N/A (Classic motorcycle design, no electronic infotainment features)

Features:

N/A (No electronic driver assistance systems)

Features:

N/A (No electronic connectivity features)

Dashboard:

Analog speedometer, tachometer, neutral indicator, high beam indicator, turn signal indicators.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months

Oil Filter Interval:

Replace with every oil change

Air Filter Maintenance:

Clean every 3,000 km (1,800 miles), replace as needed

Spark Plug Replacement:

Every 6,000-10,000 km (3,700-6,000 miles) or as per manual recommendation

Valve Clearance Check:

Every 6,000-12,000 km (3,700-7,500 miles)

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after riding in wet conditions

Engine Oil Viscosity:

SAE 20W-40 or 10W-40

Brake Fluid Type:

DOT 3 or DOT 4 (for hydraulic front brake, confirm in manual)

Fork Oil Type:

Yamaha Fork Oil, or equivalent SAE 10W fork oil (capacity per fork leg specified in manual)

Common Wear Items:

Cam chain wear, piston ring wear, primary drive chain wear, starter clutch issues, electrical connector corrosion.

Engine Performance:

Carburetor tuning instability, ignition timing issues, exhaust leaks.

Chassis:

Worn wheel bearings, steering head bearing adjustment, shock absorber damping loss.

📚 Vehicle History

Manufacturer:

Yamaha Motor Company, Japan

Founding:

Yamaha has a long history in musical instruments and entered the motorcycle industry in the 1950s.

Xs650 Lineage:

The XS650 platform was introduced in 1970 and produced with various updates until 1983. Known for its torquey parallel-twin engine based on British designs.

1981 Updates H Sh:

The 'H' and 'SH' designations typically represent minor styling or component updates over earlier models, such as changes to graphics, exhaust systems, or minor engine tuning refinements. The manual will detail these specific changes.

Production Years Xs650:

1970-1983

Manufacturing Location:

Japan

Customization:

Highly popular for customization, café racers, and bobbers due to its simple, robust engine and classic styling.

🏆 Awards & Recognition

Historical Reputation:

The XS650 is widely recognized as a reliable and enduring classic motorcycle, often praised for its character and customization potential.

Owner Satisfaction:

Generally high among owners who appreciate its classic nature and the hands-on maintenance involved.

Manual Type Certification:

Official Factory Service Manual - implies adherence to Yamaha's service standards.