1980–1984 Yamaha XJ650G Service Manual (P/N LIT-11616-01–94, LIT-11616-02–34)

• Covers the exact Yamaha XJ650G, starting at frame serial 4H7-000101, and XJ750RH, starting at serial 5G2-000101; it is not a blanket manual for every XJ650 or XJ750 variant.
• Combines Yamaha Service Manual LIT-11616-01-94 with Supplementary Service Manual LIT-11616-02-34 in one 213-page PDF.
• Covers engine removal and internal overhaul, cylinder-head and valve service, clutch and transmission repair, oil-pump work, and middle-gear and final-drive gear-lash and shim procedures.
• Details valve-clearance pad selection, ignition-timing and compression checks, YICS carburetor synchronization, carburetor disassembly and fuel-level adjustment, plus XJ750RH automatic cam-chain tensioner service.
• Includes wheel, brake, fork, steering-head, swing-arm, rear-shock, and shaft-drive repair, with dedicated XJ750RH anti-dive inspection, bleeding, adjustment, and front-fork overhaul coverage.
• Provides model wiring diagrams and circuit-level diagnosis for starting, charging, TCI ignition, lighting, signals, the self-cancelling flasher, and the XJ750RH computerized monitor system.

Service Scope and Contents

The publication is arranged as the XJ750RH supplement followed by the XJ650G base service information. Yamaha directs the technician to use the supplement with the base manual, so shared procedures are not duplicated. That structure makes the variant split clear: the XJ650G manual supplies the core air-cooled DOHC inline-four, shaft-drive, chassis, and electrical repair material, while the RH section adds the systems and service changes unique to the XJ750RH.

Those RH updates include YICS (Yamaha Induction Control System) carburetor synchronization with a shutoff tool and vacuum gauges, idle-speed adjustment, the automatic cam-chain tensioner, revised crankshaft-bearing information, front-wheel and front-brake procedures, air-pressure fork adjustment and rear-shock setup, the anti-dive unit, the starting-circuit cut-off relay, TCI ignition and sidestand relay circuitry, and the computerized LCD monitor.

Engine, Carburetion, and Shaft Drive

The engine chapter follows major repair work from removal through inspection and reassembly. It covers cylinder-head and cylinder removal, valve guides and seats, valve springs and lifters, camshafts and cam-chain components, pistons and rings, crankshaft and bearing selection, clutch, starter drive, transmission, oil pump, crankcase separation, A.C. generator, pick-up coil, engine reassembly, and remounting. Separate procedures address middle-gear servicing, lash measurement, shim selection, and drive-gear positioning. The chassis chapter continues with final-gear troubleshooting, removal, gear-lash adjustment, pinion and ring-gear setup, and drive-shaft/universal-joint service.

Periodic service data includes valve-clearance pad charts, cam-chain and ignition-timing checks, compression testing, clutch adjustment, engine and final-gear lubrication, brake inspection, steering-head adjustment, and cable maintenance. The carburetion chapter provides a section view and exploded assembly, full disassembly, body, float, and needle inspection, fuel-level adjustment, and the air-cleaner/crankcase-ventilation layout.

The manual also calls out repairs where assembly errors can cause damage. Cam caps are position-marked and must return to their original locations; uneven tightening can damage the head, caps, or camshafts. The specified crankcase stud and oil-gallery areas require correct sealant application—omitting it can reduce oil pressure and lead to crank seizure, while stray sealant must be kept away from the gallery O-ring and bearings. On the XJ750RH, bottoming the fork inner tube during teardown can damage the oil-lock valve, and both anti-dive adjusters must remain matched side to side.

Chassis and Electrical Diagnosis

Chassis coverage includes front and rear wheel removal, axle and bearing inspection, rear drum-brake service, front caliper and master-cylinder disassembly, brake-hose replacement and bleeding, fork overhaul, steering-head bearing work, swing-arm inspection and removal, rear-shock inspection, and cable and throttle maintenance. The XJ750RH supplement adds anti-dive operation diagrams, system inspection, housing removal, actuating-piston inspection, bleeding, adjustment, and the associated fork assembly procedures.

Electrical content is divided into circuits and tests rather than a single wiring sheet. It includes XJ650G and XJ750RH wiring diagrams; starting, charging, ignition, lighting, and signal circuit diagrams; component-location views; starter-relay, A.C.-generator, regulator/rectifier, pick-up-coil, ignitor, switch, and battery tests; and self-cancelling flasher checks. For the XJ750RH, the monitor section explains the warning-control switch, check cycle, LCD display, CMS control unit, battery sensor, fault tables, and display-unit replacement.

Useful visual references include the anti-dive oil-flow section views, carburetor section view, computerized monitor circuit, starting-circuit cut-off relay diagram, charging and TCI ignition circuits, and the clutch, transmission, and final-drive exploded assemblies.

Specification and Reference Data

The appendices consolidate model-specific general and maintenance specifications, component torque tables, general torque data, conversion tables, lubrication diagrams, cable routing, parts illustrations, and wiring diagrams. The technical tables cover clearances and wear limits, valve-train and cylinder inspection data, clutch and transmission limits, lubrication and oil-pressure information, brake, fork, and chassis specifications, gear-lash and shim data, carburetor settings, and electrical test values.

A dedicated special-tool section identifies equipment by name and part number. Examples include tappet adjusting tool P/N 90890-01245-00, piston ring compressor P/N 90890-04044-00, middle and final gear holding tool P/N 90890-01229-00, and electro tester P/N 90890-03021-00. This is useful before a repair is scheduled, since the manual shows which jobs depend on Yamaha-specific fixtures or testers rather than improvised substitutes.

Brake bleeding, pressurized fork and anti-dive work, spring-loaded suspension service, and engine or final-drive disassembly should be performed with the motorcycle securely supported, stored pressure released, and appropriate eye and hand protection in use.