Yamaha · Yamaha XS-1 / XS650 (1970-1985)

XS2 / TX650 / XS650

Library entry covers 1972-1985

27 factory 37 guideline

Published source

Yamaha XS650SF / XS650-2F Supplementary Service Manual (supplement to XS650E Service Manual LIT-11616-00-76)

Factory workshop manual. Covers 1979 (XS650SF / XS650-2F).

Open the source

64 items for a 1985 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Mesh screens / strainers only
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1985 Yamaha XS2 / TX650 / XS650

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

4 items

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Drive chain: check chain tension. Factory: General maintenance chart p.137: every 500 km (300 mi)
Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Drive chain: lube. Factory: General maintenance chart p.137: check tension and lube every 500 km (300 mi)

Every 1,000 mi or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 2,500 mi or 6 months

14 items

Change engine oil

Engine

Factory

Manual: Engine oil. Factory: General maintenance chart p.137: every 4,000 km (2,500 mi) or 6 months
Exhaust system: check for leakage, retighten

Engine

Factory

Factory: Maintenance intervals chart p.137: every 4,000 km or 6 months
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Idle speed: check and adjust; adjust cable free play. Factory: Maintenance intervals chart p.137: every 4,000 km or 6 months
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor synchronization: adjust. Factory: Maintenance intervals chart p.137: every 4,000 km or 6 months
Check / set ignition timing

Ignition and electrics

Factory

Manual: Ignition timing: check and adjust. Factory: Maintenance intervals chart p.137: every 4,000 km or 6 months
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery: check specific gravity and breather pipe. Factory: General maintenance chart p.138: every 4,000 km or 6 months
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Contact breaker points: check condition, adjust gap. Factory: Maintenance intervals chart p.137: every 4,000 km or 6 months
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch: adjust free play. Factory: General maintenance chart p.137: every 4,000 km or 6 months
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Factory

Manual: Brake pedal and change pedal shaft: lubricate. Factory: General maintenance chart p.137: every 4,000 km or 6 months
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Center and side stand pivots and kick crank boss: lubricate. Factory: General maintenance chart p.137: every 4,000 km or 6 months
Grease swingarm pivot

Rear suspension and frame

Factory

Manual: Rear arm pivot shaft: grease until new grease shows. Factory: General maintenance chart p.137: every 4,000 km or 6 months
Check brake pads and discs

Brakes

Factory

Manual: Brake system: adjust free play, replace shoes/pad if necessary. Factory: General maintenance chart p.137: every 4,000 km or 6 months
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings: check for smooth rotation. Factory: General maintenance chart p.138: every 4,000 km or 6 months
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cable: apply cable lube. Factory: General maintenance chart p.137: every 4,000 km or 6 months

Every 3,000 mi or 12 months

7 items

Adjust cam chain tensioner

Engine

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 5,000 mi or 12 months

8 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance: check and adjust when engine is cold. Factory: Maintenance intervals chart p.137: initial 1,000 and 5,000 km, then every 8,000 km
Check engine breather and oil return

Engine

Factory

Manual: Crankcase ventilation system: check hose. Factory: Maintenance intervals chart p.137: every 8,000 km or 12 months
Clean oil strainers / mesh screens

Engine

Factory

Manual: Oil filter: clean element in solvent. Factory: General maintenance chart p.137: every 8,000 km or 12 months
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs: check condition, adjust gap. Factory: Maintenance intervals chart p.137: every 8,000 km or 12 months
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter: clean with compressed air. Factory: General maintenance chart p.137: every 8,000 km or 12 months
Fuel hose: check for cracks or damage

Fuel and air

Factory

Factory: Maintenance intervals chart p.137: every 8,000 km or 12 months
Inspect generator brushes and commutator

Ignition and electrics

Factory

Manual: A.C. generator: replace generator brushes. Factory: Chart p.138: 8,000 km column; remark says replace at initial 9,000 km
Cam chain: check and adjust chain tension

Final drive

Factory

Factory: Maintenance intervals chart p.137: initial 1,000 km, then every 8,000 km

Every 6,000 mi or 12 months

5 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 6,000 mi or 2 years

1 item

Lubricate and check automatic advance unit

Ignition and electrics

Guideline

Every 8,000 mi or 2 years

1 item

Replace spark plugs

Engine

Guideline

Every 10,000 mi or 2 years

4 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Factory

Manual: Front fork oil: drain completely, refill. Factory: General maintenance chart p.138: every 16,000 km (10,000 mi) or 24 months
Repack / replace steering head bearings

Front end

Factory

Manual: Steering ball bearing and races: repack. Factory: General maintenance chart p.138: repack every 16,000 km (10,000 mi)
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Wheel bearings: repack. Factory: General maintenance chart p.138: repack every 16,000 km (10,000 mi)

Every 12,000 mi or 2 years

1 item

Replace air filter element

Fuel and air

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.