Yamaha XJ650G/XJ750RH Service Manual Set, 1980–1984 (P/N LIT-11616-01-94)

Yamaha specifies using the supplement together with the base manual. The base supplies shared service procedures, while the supplement adds XJ750RH-specific systems and changes.

Check the exact G or RH model designation before choosing this set; coverage does not extend to every XJ650 or XJ750 variant.

PDF Search, Navigation and Printing

Text search and wiring detail: PDF text search is not available. Two embedded bookmarks mark the file parts, without chapter-level navigation. Small wiring-diagram labels require zooming.

One printable, English-language PDF contains 213 pages, including three opening front-matter pages. The supplement’s four additional fork-service pages and the base manual’s final memo page are already included in these counts.

Engine Overhaul, Shaft Drive and RH System Service

The coverage highlights below are a selection of the contents. Other included topics include fuel-petcock inspection and tubeless-wheel checks.

• Engine repair: Engine removal and internal overhaul, cylinder-head and valve service, clutch and transmission repair, oil-pump work, reassembly, and remounting.

• Shaft drive: Middle-gear and final-drive troubleshooting, gear-lash measurement, shim selection, pinion and ring-gear positioning, and drive-shaft/universal-joint service.

• Periodic maintenance: Valve-clearance pad selection, cam-chain and ignition-timing checks, compression testing, clutch adjustment, lubrication, brake inspection, and cable maintenance.

• Carburetion: Carburetor disassembly, component inspection, fuel-level adjustment, synchronization, and XJ750RH YICS procedures using a shutoff tool and vacuum gauges.

• Brakes and suspension: Wheel, brake, fork, steering-head, swing-arm, and rear-shock service, with dedicated XJ750RH anti-dive inspection, bleeding, adjustment, and fork-overhaul procedures.

• Electrical diagnosis: Model wiring diagrams and circuit tests for starting, charging, TCI ignition, lighting, signals, the self-cancelling flasher, and the XJ750RH computerized monitor.

Written primarily for Yamaha dealers and qualified mechanics, these manuals assume a basic understanding of motorcycle repair concepts and procedures.

Internal Engine Repair and Assembly

Step-by-step procedures cover crankcase separation, cylinder and piston removal, engine reassembly, and remounting. Inspection sections address valve guides and seats, valve springs and lifters, camshafts, cam-chain components, piston rings, crankshaft bearings, and transmission components.

The engine chapter also covers starter-drive inspection, A.C. generator and pick-up-coil removal, oil-pump disassembly, rotor-clearance checks, and relief-valve inspection. A damaged oil-pump housing calls for pump-assembly replacement.

Assembly cautions: Position-marked cam caps and even tightening matter because incorrect assembly can damage the head, caps, or camshafts. The crankcase instructions also identify sealant errors that can reduce oil pressure and cause crank seizure, while keeping sealant away from the oil-gallery O-ring and bearings.

Middle Gear and Final-Drive Setup

The shaft-drive troubleshooting chart distinguishes bearing-related rumble, gear-lash noise, and loose flange or universal-joint connections. Gear-positioning sections explain how component markings relate to shim selection, with separate checks for final-gear lash and ring-gear thrust clearance.

Carburetor Inspection and RH Updates

A carburetor section view and exploded assembly accompany checks of the body, fuel passages, floats, needle valve, vacuum piston, and diaphragm. Fuel-level adjustment is covered alongside the air-cleaner and crankcase-ventilation layout.

The RH supplement adds the YICS synchronization method, automatic cam-chain tensioner installation, and revised crankshaft main-bearing installation information. Pilot-mixture screws are factory preset; the manual cautions against changing those settings.

Chassis Repair and Anti-Dive Limits

The chassis procedures extend to axle inspection, wheel-bearing replacement, rear drum-brake service, front-caliper and master-cylinder disassembly, brake-hose replacement, and bleeding. Steering-head bearing work, swing-arm removal and lubrication, rear-shock inspection, and throttle maintenance are also covered.

XJ750RH suspension: Anti-dive oil-flow section views explain operation alongside actuating-piston inspection and fork assembly procedures. The anti-dive valve housing is replaced as an assembly if faulty; it is not internally disassembled.

The RH fork instructions warn that bottoming the inner tube during teardown can damage the oil-lock valve assembly, and both anti-dive settings must remain matched.

Brake bleeding, pressurized fork and anti-dive work, spring-loaded suspension service, and engine or final-drive disassembly require secure support, release of stored pressure, and appropriate eye and hand protection.

Circuit Tests and Computerized Monitor Diagnosis

Electrical coverage includes component-location views, starting-circuit cut-off relay diagrams, charging circuits, TCI ignition circuits, and self-cancelling flasher checks. Tests address the starter motor and relay, A.C. generator, regulator/rectifier, pick-up coils, ignition coils, ignitor, switches, and battery.

The XJ750RH computerized monitor section explains the warning-control switch, check cycle, LCD display, CMS control unit, and battery sensor. Fault tables distinguish display, connector, wiring, switch, and control-unit problems, with procedures for display-unit removal, cleaning, and replacement.

Reference Tables and Workshop Preparation

The appendices provide model-specific general and maintenance specifications, inspection clearances and wear limits, component and general torque tables, lubrication and oil-pressure information, carburetor settings, and electrical test values. Conversion tables, lubrication diagrams, cable routing, and exploded parts illustrations support the repair chapters.

Special tools: Identified equipment includes tappet adjusting tool P/N 90890-01245-00 and 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 are also listed.

These references support repair planning by identifying jobs that depend on dedicated fixtures or testers. Dimensioned drawings are included for constructing final-gear service tools.

Valve-Clearance and Generator-Test Examples

For both models, the cold-engine valve-clearance specifications are 0.11–0.15 mm for intake valves and 0.16–0.20 mm for exhaust valves, supported by adjusting-pad selection charts.

Generator test data specifies field-coil resistance of 4.0 Ω ±10% and stator-coil resistance of 0.46 Ω ±10%, both at 20°C (68°F), alongside the related circuit checks.