🏷️ Basic Information Identification Make: Yamaha Model: XS650E Production Years Covered: 1978, 1979, 1980, 1981 👋 Introduction Market Position Motorcycle Segment: Mid-size, parallel-twin motorcycle known for its classic styling and strong parallel-twin engine. Competitive Analysis Key Competitors: Competed against models like the Triumph Bonneville, Kawasaki KZ650, and Honda CB750 (though the XS650 leaned more towards the Bonneville ethos). Key Features Engine Type: Air-cooled, SOHC, parallel-twin engine with a distinctive 270-degree crankpin arrangement, providing a unique firing order and exhaust note. Handling: Generally praised for its balanced chassis and comfortable riding position, making it suitable for touring and everyday use. Design Philosophy: Emphasized classic motorcycle aesthetics with modern (for its era) engineering. 📋 Manual Details Coverage Areas Primary Focus: Workshop Service and Repair Page Count Total Pages: 212 Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete disassembly, inspection, repair, and reassembly of the XS650 engine, including cylinder head, pistons, crankshaft, transmission components, and lubrication system. Fuel System: Carburetor tuning, maintenance, and overhaul (Mikuni VM series); fuel tank, petcock, and fuel lines. Ignition System: CDI ignition system components, timing adjustments, spark plug specifications, and troubleshooting. Electrical System: Wiring diagrams, charging system (alternator, rectifier/regulator), battery maintenance, lighting, starting system, and fuses. Drivetrain: Clutch operation and adjustment, primary drive, final drive chain and sprockets, gearbox inspection and repair. Brakes: Front disc brake system (caliper, master cylinder, fluid) and rear drum brake maintenance and adjustment. Suspension: Front fork service (oil changes, seal replacement), rear shock absorber inspection and replacement, linkage maintenance. Steering: Handlebar removal, steering head bearing adjustment and replacement. Wheels And Tires: Wheel bearing maintenance, tire pressure recommendations, and basic wheel truing. Frame And Bodywork: Frame inspection, seat, tank, and fender removal/installation. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake bleeding. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common problems across all major systems. Repair: Detailed step-by-step instructions for component repair, overhaul, and replacement. Rebuilds: Comprehensive instructions for complete engine and gearbox rebuilds. Technical Depth Depth Level: Full Workshop Manual - Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Print Quality Quality Description: Digital reproduction, clarity optimized for screen viewing and printing. Likely to contain clear diagrams and text. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, SOHC, parallel-twin Displacement: 653 cc Bore X Stroke: 75.0 mm x 74.0 mm Compression Ratio: 8.4:1 (typical, may vary slightly by year) Crankshaft Configuration: 270-degree Performance Horsepower: Approx. 53 PS (39 kW) @ 6500 rpm (varies by year and tuning) Torque: Approx. 5.5 kg-m (54 Nm; 40 lb-ft) @ 5000 rpm (varies by year and tuning) Fuel System Carburetor Type: Dual Mikuni VM34SS (2x 34mm constant velocity carburetors) Fuel Capacity: 17 Liters (4.5 US gal) - typical for the E model Lubrication System: Wet sump Oil Capacity: 2.4 Liters (2.5 US qt) with filter change 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Primary Drive: Straight-cut gears, 2.06:1 ratio Final Drive: O-ring sealed chain drive Clutch Type: Wet, multi-plate Features Gearbox Design: Robust and generally reliable, but clutch adjustment and maintenance are critical. 📐 Dimensions Exterior Length: Approx. 2200 mm (86.6 in) (varies slightly by model year and configuration) Width: Approx. 800 mm (31.5 in) (varies) Height: Approx. 1150 mm (45.3 in) (varies) Weights Dry Weight: Approx. 190 kg (419 lbs) (varies) Wet Weight: Approx. 205 kg (452 lbs) (varies) 🛡️ Safety Features Ratings Safety Features Era: Standard for its time; focused on mechanical reliability rather than electronic safety aids. Active Features Brakes: Front: Single disc brake, Rear: Drum brake. Dual discs became optional or standard on later 'Special' variants or international markets. Passive Features Lighting: Halogen headlamp, taillight, turn signals. 💡 Technology Features Infotainment Infotainment System: None (Classic motorcycle design, analog instrumentation). Driver Assistance Assistance Features: None (Classic motorcycle design). Connectivity Connectivity Features: None (Classic motorcycle design). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 km (2,000 - 3,000 miles) or 6 months, whichever comes first. Manual will provide precise intervals. Valve Adjustment Interval: Every 6,000 - 10,000 km (4,000 - 6,000 miles). Specific procedure and clearances in manual. Chain Lubrication Adjustment: Every 1,000 km (600 miles) or as needed, especially after wet riding. Manual specifies slack adjustment. Fluid Specifications Engine Oil Type: SAE 20W-40 or 20W-50 motorcycle specific oil meeting API SF or SG classification. Manual will confirm exact specification. Fork Oil Type: Yamalube Fork Oil (e.g., 10W) or equivalent motorcycle fork oil. Manual will specify viscosity and volume. Brake Fluid Type: DOT 3 or DOT 4 brake fluid (for the front disc brake). Known Issues Charging System: Original rectifiers/regulators can be prone to failure. Upgraded solid-state units are common aftermarket...