1980-1983 Yamaha XJ650G Service Manual
Complete factory repair guide for XJ650G and supplementary XJ750RH specifications. Covers engine overhaul, carburetion, chassis, and electrical systems with detailed torque specifications and diagrams.
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Sample pages from the 1980-1983 Yamaha XJ650G Service Manual manual
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Models Covered & Key Technical Specifications
Yamaha XJ650G, XJ750RH — 1980–1984 Operational Technical Specification | XJ Series Service Compendium.
- Established End Play: 0.040 mm (0.0016 in) is designed for the crankshaft main journal run-out maximum measurement Bounds.
- Calibrated Power Framework: For optimal performance, 14 hp at 5,000 r/min represents the AC generator maximum rated output Parameters.
- Operational Ambient Limits: Engine displacement spans 653–748 cc (39.85–45.64 cu.in) across model variants Standards.
- Essential Dimensional Limits: The cylinder bore requires 63.00 mm (2.480 in) standard size with wear limit reaching 63.10 mm (2.484 in) Topology.
- Baseline Torque Data: Relief valve setting is specified as 5.0 kg/cm² (71 psi) for the oil pressure system Protocol.
- Integral Measurement Bounds: Fuel tank capacity reaches 13–19 lit (3.4–5.0 US gal) across XJ650G and XJ750RH configurations Matrix.
Professional Workshop Service Manual & Technical Specifications
Systematic Procedure Electrical Manual: Motorcycle Yamaha XJ Service Manual: Comprehensive Guide for XJ650G and XJ750RH Maintenance System-Standards
Calibration-Scope: XJ650G (1980-1983) and XJ750RH models // Calibration-Scope: Service operations and electrical system documentation / troubleshooting methodology // Calibration-Scope: Complete technical specifications for four-cylinder air-cooled engines.
| Metric | Operational-Logic | Calibration-Standards |
|---|---|---|
| Engine Systems | Carburetion and ignition data documented | See Chapters 3-4 |
| Chassis Components | Brake and suspension specifications included | Complete procedures documented |
| Electrical Circuits | Starting, charging, and lighting systems | See Chapter 6 wiring diagrams |
Diagnostic procedures address engine overhauling and carburetion tuning, while factory procedures are documented for periodic maintenance and chassis servicing. The manual examines valve clearance adjustment protocols, cam chain tensioner operation, and compression pressure measurement. Troubleshooting methodologies span the starting circuit cut-off relay, sidestand relay operation, and ignition timing verification using magnetic pickup coil systems. Safety procedures are documented for anti-dive suspension systems, brake fluid level monitoring, and clutch adjustment mechanisms.
Systematic Topology
Brake system specifications are included for front disc and rear drum configurations across both model variants. The document provides torque specifications for bolt stretch prevention on critical engine fasteners, including cylinder head nuts, cam sprocket bolts, and crankshaft bearing surfaces. Complete specifications address engine oil capacity differentials between total fill and service intervals, with recommended lubricant grades listed for varying ambient temperature conditions.
Technical Framework
Fluid capacities are listed for engine oil, fork oil, and final gear oil systems, ensuring proper levels for optimal system performance. Installation guidelines are provided for wheel bearing replacement procedures, brake pad servicing, and fork seal reassembly sequences. The manual contains comprehensive wiring diagrams depicting the XJ650G charging system configuration, featuring the three-phase regulated alternator output specifications and IC voltage regulator operational parameters.
Core Standard
Tool requirements are listed for specialized equipment including valve guide reamers, piston ring compressors, and the proprietary fork cylinder composition holder for front suspension work. Accurate understanding of the module architecture enables technicians to address wear conditions in transmission gear teeth, clutch plate friction surfaces, and shaft drive component engagement patterns. Systematic documentation of middle gear lash measurement procedures ensures proper bevel gear positioning and damper assembly function.
Modular Methodology
The manual documents torque specifications for the shaft drive system, including middle gear drive pinion holder applications and final gear bearing retainer removal using specialized tooling. Systematic reference data covers crankshaft main bearing selection using color-coded bearing sets, with proper clearance measurement using Plastigage methodology. Comprehensive threshold documentation includes camshaft-to-cap clearance limits and valve stem-to-guide clearance tolerances for intake and exhaust valve assemblies.
The document provides detailed specifications for the Computerized Monitor System operational logic, including liquid crystal display indicator interpretation and warning control switch functionality. Specifications address battery fluid level sensor installation positioning and microcomputer unit replacement procedures for instrument panel assembly work. Complete electrical system documentation encompasses the breakerless transistor control ignition system with magnetic pickup coil signal generation and electronic advance circuit operation.
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