XJ650G

Basic color

Dimensions:

Overall length

Overall width

Overall height

Seat height

Wheelbase

Minimum ground clearance

Caster (steering head angle)

Trail

Black Blue or New Ruby Red

2,165 mm (85.2 in)

860 mm (33.9 in)

1,180 mm (46.5 in)

750 mm (29.5 in)

1,445 mm (56.9 in)

150 mm ( 5.9 in)

29°

124 mm (4.88 in)

Weight: Net

203 kg (447 lb)

Engine: Type

Bore x stroke x cylinders

Displacement

Compression ratio

D.O.H.C. air-cooled, gasoline

63.0 x 52.4 mm x 4 (2.480 x 2.063 in x 4)

653 cc (39.85 cu. in)

9.2 : 1

Lubrication:

Lubrication system

Delivery pump type

Pressure lubricated, wet sump

Trochoid

Carburetion:

Manufacture

Type

Rated venturi size

HITACHI

HSC32, constant velocity

32 mm (1.26 in)

Air filter:

Dry type element

Ignition: 
Type 
Spark plug

Battery ignition (Full transistor ignition) 
BP7ES(NGK) or W22EP (ND)

Charging:

Type

Manufacture, I.D. No.

Maximum output

Battery type

Battery dimensions

Regulator/Rectifier

Regulating voltage (No. load)

Three-phase, regulated alternator

HITACHI, LD119-08

14V 19A

12N12A-4A

80 x 160 x 134 mm (3.15 x 6.30 x 5.28 in)

S8534, I.C. type, full wave

14.2 - 14.8V

Starting:

Electric starter

Primary drive:

Type

Teeth,

ratio

Spur gear

97/58

1.672

Clutch:

Wet, multiple disc

Transmission:

Type

Constant mesh, 5-speed drum shifter

XJ650G

Teeth, ratio 1st

2nd

3rd

4th

5th

35/16 2.187

30/20 1.500

30/26 1.152

28/30 0.933

26/32 0.812

Secondary drive:

Type

Transmission output:
Type, teeth, ratio

Middle gear case:
Type, teeth, ratio

Final gear case:
Type, teeth, ratio

Shaft drive

Spur gear, 49/36, 1.361 1

Bevel gear, 19/18, 1.055

Bevel gear, 32/11,2.909

Chassis:

Frame

Suspension: 
Front (type, travel)
Rear (type, travel}

Tires: 
Front

Rear

Brakes: 
Front
Rear

Fuel tank: 
Total
Reserve

Wheels: 
Front
Rear

Tubular steel double cradle

Telescopic fork 150 mm (5.91 in) 
Swing arm, 80 mm (3.15 in)

3.25H19-4PR,Tubeless

130/90-16 67H, Tubeless

Single hydraulic disc
Drum brake

13 Lit (3.4 US. gal)
3.4 Lit (0.8 US. gal)

MT1.85 x 19, Cast Aluminum
MT3.00 x 16, Cast Aluminum

Engine oil capacity:

Total amount

Oil and filter change

Oil change Recommended lubricant:

If temperature does not go below 5"C (40 F)

If temperature does not go above 15~C (60 F)

3,200 cc (3.4 US. qt)

2,650 cc (2.8 US. qt)

2,350 cc (2.5 US. qt)

SAE 20W/40SE motor oil

SAE 10W/30SE motor oil

Cranking pressure (at seal level):

Maximum difference between cylinders:

11 kg/cm² (156 psi)

1 kg/cm² (14 psi)

Dimensions

Standard size

Wear limit

Intake

A

B

C

36.80 mm (1.449 in)

28.0 mm (1.102 in)

8.50 mm (0.335 in)

36.65 mm (1.443 in)

27.85 mm (1.096 in)

---------------------

Exhaust

A

B

C

35.80 mm (1.449 in)

28.0 mm (1.102 in)

7.8 mm (0.307 in)

35.65 mm (1.404 in)

27.85 mm (1.096 in)

---------------------

Inner
Intake/Exhaust

Outer
ln:ake/Exhaust

Free length

35.9 mm (1.413 in)

39.5 mm (1.555 in)

Spring rate

2.36 kg/mm (132.2 lb/in)

4.58 kg/mm (256.5 lb/in)

Installed length (valve closed)

31.0 mm (1.220 in)

34.0 mm (1.339 in)

Installed pressure

(valve closed)

9.0 kg (19.8 lb)

19.1 kg (42.1 lb)

Compressed length (valve open)

IN: 22.8 mm (0.898 in) 
EX:23.5 mm (0.925 in)

IN: 25.8mm(1.016 in) EX:26.5mm(1.043 in)

Wire diameter

2.8 mm (0.110 in)

3.9 mm (0.154 in)

Number of windings

7.75

6.1

Winding O.D.

20.6 ⁺°*³ mm (0.811**⁰¹² in)

29.4_° mm (1.157^₀°₀₁₂ in)

Clearance (Cold engine)

0.11 -0.15 mm (0.004- 0.006 in)

"A" head diameter

33 ± 0.1 mm (1.2992 ± 0.0039 in)

"B" face width

2.3 mm (0.0906 in)

"C" seat width

1.0 ± 0.1 mm (0.0394 ± 0.0039 in)

"D" margin thickness (minimum)

1.2 ±0.2 mm (0.0472 ±0.0079 in)

Stem diameter (O.D.)

-,-0.010

⁷-0.025 ^mm

tn 07RR -0.0004 . . ^(0>2756 -0.0010 ^m)

Guide diameter (|.D.)

-,+0.012 ' q mm

(0.2756 ⁺°^000B in)

Stem-to-guide clearance

0.010 ~0.037mm (0.0004 ~ 0.0015 in)

Clearance (Cold engine)

0.16~ 0.20mm (0.006-0.008 in)

"A" head diameter

28 ± 0.1 mm (1.2205 ±0.0039 in)

"B"face width

2.3 mm (0.0905 in)

"C" seal width

1.0 ± 0.1 mm (0.0394 ± 0.0039 in)

"D" margin thickness (minimum)

1.0 ±0.2 mm (0.0392 ± 0.0079 in)

Stem diameter (O.D.)

7 ^-0.025 mm
^-0.040

(0.2756 ^-0.0010 in)
^-0.0016

Guide diameter (I.D.)

7 ^+0.012 mm
^-0.0

(0.2756 ^-0.0005 in)
^-0.0

Stem-to-guide clearance

0.025 ~ 0.052 mm 
(0.0010 ~ 0.0020 in)

Cylinder and piston:

Cylinder material

Cylinder liner

Bore size: 
standard 
Wear limit

Cylinder taper limit

Cylinder out-of-round limit

Piston clearance: 
standard

maximum

Piston weight (include rings, pin and clips)

Aluminum alloy

Pressed in; special cast iron

63.00 mm (2.4803 in)
63.10 mm (2.4843 in)

0.05 mm (0.0020 in)

0.01 mm (0.0004 in)

0.030 ~ 0.050 mm 
(0.0012- 0.0020 in)
0.1 mm (0.0039 in)

213 g (7.520oz)

Piston rings:

Top

2nd

Oil

Design

Barrel

Taper

Expander

End gap (installed): standard

0.15-0.35 mm (0.0059 ~ 0.0138 in)

0.15-0.35 mm (0.0059 ~ 0.0138 in)

0.3-0.9 mm (0.0118 -0.035 in)

limit

1.0 mm (0.0394 in)

1.0 mm (0.0394 in)

1.5 mm (0.0591 in)

Side clearance: standard

0.03-0.07 mm (0.0012 ~ 0.0028 in)

0.02-0.06 mm (0.008 -0.0024 in)

-----

limit

0.15 mm (0.0059 in)

0.15 mm (0.0059 in)

—--

Crankshaft:

Crank journal/bearing oil clearance

Main journal run-out (maximum)

0.040-0.064 mm (0.0016-0.0025 in)

0.040 mm (0.0016 in)

Connecting rods

Weight

Rod bearing oil clearance

345 g (12.2 oz)

0.03 - 0.09 mm (0.0012-0.0035 in)

Oil pump:

Housing-to-outer rotor clearance

Outer rotor-to-inner rotor clearance

0.09- 0.15 mm (0.0035- 0.0059 in)

0.12 mm (0.005 in) or less

Clutch:

Friction plate:  
thickness
quantity
minimum thickness

Clutch plate: 
thickness
quantity
warp limit

Clutch spring: 
length
quantity
minimum length
spring rate

Clutch lever freeplay (at lever pivot point)

3.0 mm (0.12 in)
8 
2.8 mm (0.11 in)

1.6 mm (0.063 in)
7 
0.05 mm (0.0020 in)

40.1 mm (1.579 in)
5 
39.1 mm (1.539 in) 
1.184 kg/mm (66.3 lb/in)

2- 3 mm (0.08-0.12 in)

Transmission shaft run-out maximum:

0.08 mm (0.0031 in)

Middle gear case lash:

0.1 - 0.2 mm (0.0039 - 0.0079 in)

Manufacturer

Model I.D.No.

Main jet'

Needle jet

Pilot jet

Starter jet

Jet needle

HITACHI

4H700

#  110

0 3.2

#  40

# 40(0 0.9)

Y-10

Fuel level

Pilot screw

Air jet, Main

Air jet, Pilot

Throttle valve

Float valve seat

Engine idle speed

3±1 mm (0.118+0.039 in)

Preset

#  50

#  195

32 mm (1.26 in)

0 2.0

1,050 r/min

Wheels and tires:
Rim run-out: 
vertical
horizontal

2.0 mm (0.079 in) 
2.0 mm (0.079 in)

Tire pressure (cold):

Front

Rear

Up to 90 kq (198 lb) load*

90 kg (198 lb) -160 kg (353 lb) load*

160 kg (353 lb)~230 kg (507 lb) load*
(maximum load)

High speed riding

Minimum tire tread depth

1.8 kg/cm² (26 psi)

2.0kg/cm²(26psi)

2.0 kg/cm² (28 psi) 

2.3 kg/cm² (36 psi)

0.8 mm (0.03 in)

2.0 kg/cm² (28 psi)

2.3 kg/cm² (32 psi)

2.8 kg/cm² (40 psi)

2.5 kg/cm² (40 psi)

0.8 mm (0.03 in)

Brakes:

Recommended fluid

Pad wear limit

Rear brake lining wear limit

Brake disc maximum deflection

Brake disc minimum thickness

Front brake free play (end of lever)

Rear brake free play (end of pedal)

DOT =3

6.5 mm (0.26 in)

2 mm (0.08 in)

0.15 mm (0.006 in)

3.5 mm (0.26 in)

5.0^ 8.0 mm (0.2-0.3 in)

20 ~ 30 mm (0.8 - 1.2 in)

Front forks

Travel

Spring free length

Spring preload length

Spring rate: 
0 -100 mm (0~3.94 in)
100-150 mm (3.94~5.91 in)

Fork oil capacity leach side)

Oil type

150 mm (5.91 in)

606 mm (23.86 in)

571 mm (22.48 in)

0.475 kg/mm (26.6 lb/in)
0.626 kg/mm (35.1 lb/in)

262 cc (9.24 oz)

Yamaha Fork Oil 10Wt or equivalent

Rear shock absorbers:

Spring free length

Spring preload length

Spring rate: 
0 ~ 55 mm (0~ 2.17 in)
55 -80 mm (2.17-3.15 in)

Travel

232.5 mm (9.15 in)

216.5 mm (8.52 in)

1.6 kg/mm (89.6 lb/in) 
2.2 kg/mm (123.2 lb/in)

80 mm (3.15 in)

Spark plug:

Electrode gap

NGK BP7ESorND W22EP

0.7 - 0.8 mm (0.023 - 0.032 in)

Spark plug cap resistance:

5.0kft (No. 1,No.4), 10kft (No. 2, No. 3)

Pick up coil: Resistance

700ft ± 20%at20°C(68°F)

Ignition coil type: Spark gap

Primary resistance

Secondary resistance

HITACHI CM12-09

2.5 Ω± 10%at20°C(68^oFj

11kΩ± 20% at 20°C (68°F)

Starter motor type:

Armature coil resistance

Brush length: 
standard 
minimum

Brush spring pressure

Armature mica undercut

Nippon Denso ADB4D2

0.014Ω ± 6% at 20°C (68°F)

12.0 mm (0.472 in)
8.5 mm (0.33 in)

800 ± 150g (28.24 ± 5.30 oz)

0.6 mm (0.024 in)

Battery type:

Charging rate

G.S. 12N12A-4A

1.2 Amps for 10 Hours

Generator type:

Output

Field (inner) coil resistance

Stator (outer) coil resistance

HITACHI LD119-08

14V-19A at 5,000 r/min

4.0Ω ±10%at20^oC(68°F)

0.46 Ω ± 10% at 20°C (68°F)

Regulator type:

Regulated voltage

Allowable amperage

I.C. (S8534)

14.5 ± 0.3V

3A

Starter relay switch:

Cut-in voltage

HONDA LOCK

8V

Headlight:

Tail/brake light:

Flasher light:

License light:

Pilot lights:
Turn
High beam
Neutral
Oil level 
Meter light

12V.50W/40W

12V, 8W (3CP)/27W (32CP)

12V, 27W(32CP) x4

12V, 8W (3CP) x2

12V,3.4Wx2 
12V, 3.4W x 1 
12V, 3.4Wx 1 
12V,3.4W x 1 
12V,3.4Wx2

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

m-kg

ft-lb

ENGINE:

Cylinder head

Nut

M10 P1.25

12

3.2

23.1

Apply oil.

Cylinder head cover

Bolt

M6 P1.0

20

1.0

7.2

Spark plug

—

4

2.0

14.5

Cylinder

Nut

M8 P1.25

2

2.0

14.5

Cam chain case Front & Rear

Cam shaft cap

Bolt

M6 P1.0

20

1.0

7.2

Tighten in 3-stages.

Cam sprocket

Bolt

M7 P1.0

4

2.0

14.5

Cam chain tensioner adjustment lock nut

Nut

M8 P1.25

1

0.9

6.5

Cam chain tensioner adjustment lock bolt

Bolt

M6 P1.0

1

0.6

4.3

Connecting rod

Nut

M7 P0.75

8

2.5

18.1

Generator (rotor)

Bolt

M10 P1.25

1

5.5

39.8

Drain plug

Bolt

M14 P1.5 M8 P1.25

1

1

4.3 1.6

31.0 11.6

Crankcase drain Middle gear case drain

Oil filter

Bolt

M20 P1.5

1

1.5

11.0

Pump cover

Screw

M6 P1.0

0.7

5.1

Strainer cover

Bolt

M6 P1.0

13

1.0

7.2

Crankcase

Flange Bolt

M8 P1.25 M6 P1.0

12 27

2.4 1.2

17.5 8.7

Clutch boss

Nut

M20 P1.0

1

7.2

52.0

Clutch spring screw

Bolt

M6 P1.0

5

1.0

7.2

Change pedal

Bolt

M6 P1.0

1

1.0

7.2

Neutral switch

—

M10 P1.25

1

2.0

14.5

Exhaust pipe

Nut

M6 P1.0

8

1.0

7.2

SHAFT DRIVE:

—Middle Gear —

Drive Shaft

Nut

M34 P1.5

1

11

80.0

Stake.

Mount cover

Screw

M8 P1.25

4

2.5

18.1

Stake.

Driven shaft

Nut

M14 P1.5

1

12

87.0

Use LOCKTITE: Stake.

Bearing cap

Flange Bolt

M8 PI.25

4

2.5

18.1

- Final Gear —

Drive shaft

Nut

M14 P1.5

1

11

80.0

Bearing housing

Flange Bolt

M10 P1.25

2

2.3

16.6

Bearing housing

Nut

M8 PI .25

6

2.3

16.6

Oil mount screw

Plug

M14 P1.5

1

2.3

16.6

Oil drain screw

Plug

M14 Pi .5

1

2.3

16.6

Bearing retainer

—

M65 P1.5

1

11

80.0

Left hand screw

CHASSIS:

Engine Mounting Bolt

Front, upper
Front, under

Rear

Nut

Bolt

Nut

M10 P1.25

M10 P1.25

M12 P1.25

1

2

1

4.2

4.2

7.0

30.4

30.4

50.6

Part to be tightened

Part name

Thread size

Q'ty

Tightening torque

Remarks

m-kg

ft-lb

Engine Mounting Stay

Front

Bolt

M8 P1.25

4

2.0

14.5

Handle crown & Steering shaft

Rolt

Bolt

M14 P1.25 M8 P1.25

1

1

5.4 2.0

39.1 14.5

Handle crown & Inner tube

Nut cap

M8 P1.25

1

2.0

14.5

Handle crown & Handle holder

Bolt

M8 P1.25

2

2.0

14.5

Front fork

Under bracket & Inner tube

Bolt

M8 P1.25

4

2.0

14.5

Front wheel shaft

Nut Castle

M14 P1.5

1

10.7

77.4

Front wheel Axle pinch bolt

Nut self locking

M8 P1.25

2

2.0

14.5

Pivot shaft

Bolt

M22 P1.5

1

0.55

4.0

Taper roller bearing

Rear wheel shaft

Nut castle

M14 P1.5

1

10.7

77.4

Rear shock absorber (Upper)

Nut cap

M10 P1.25

2

3.0

21.7

Rear shock absorber (Lower)

L Nut cap R Bolt

M10 P1.25

2

3.0

21.7

Footrest

Nut

M10 P1.25

2

4.2

30.4

Tension bar & Brake plate

Bolt

M8 P1.25

1

2.0

14.5

Tension bar & Rear arm

Bolt

M8 P1.25

1

2.0

14.5

Camshaft lever & Camshaft

Bolt

M6 P1.0

1

0.9

6.5

Disc brake section

Brake disc & Hub (Front)

Bolt

M8 P1 .25

12

2.0

14.5

Lock washer

Master cylinder & Brake hose (Front)

Bolt union

M10 P 1.25

1

2.6

18.8

Brake hose & Joint

Bolt union

M10 P1.25

1

2.6

18.8

Caliper & Brake hose

Bolt union

M10 P1.25

1

2.6

18.8

Caliper & Front fork (Front)

M8 PI.25

1

2.6

18.8

Caliper bleed screw (Front)

M8 P1.25

1

0.6

4.3

•

Front fender

Bolt

M8 P1.25

4

1.0

7.2

Master cylinder cap

Screw

M5 P0.8

2

0.18

1.3

Pivot shaft

Bolt

M22 P1.5

1

10.0

72.3

Lock washer

Final gear & Rear arm

Nut

M10 P1.25

4

4.2

30.4

Cross Joint

Hexagon bolt with washer

M8 P1.25

4

4.4

31.8

Muffler bracket & Frame

Bolt

M10 P1.25

3

4.3

31.1

Rear fender

Bolt

M10 P1.25

2

3.2

23.1

Muffler bracket & Muffler

Bolt

M10 P1.25

2

2.5

18.1

Master cylinder & Master cylinder bracket

Bolt

M6 P1.0

2

0.9

6.5

A (Nut)

B

(Bolt)

General torque specifications

m-kg

ft-lb

10 mm

6 mm

0.6

4.5

12 mm

8 mm

1.5

11

14 mm

10 mm

3.0

22

17 mm

12 mm

5.5

40

19 mm

14 mm

8.5

51

22 mm

16 mm

13.0

94

METRIC TO INCH SYSTEM

KNOWN

MULTIPLIER

RESULT

TORQUE

m-kg

7.233

ft-lb

m-kg

86.80

in-lb

cm-kg

0.0723

ft-lb

cm-kg

0.8680

in-lb

WT.

kg

2.205

lb

9

0.03527

oz

FLOW /

DISTAMCE

km/lit

2.352

mpg

km/hr

0.6214

mph

km

0.6214

mi

m

3.281

ft

m

1.094

yd

cm

0.3937

in

mm

0.03937

in

CAPACITY

cc (cm³)

0.03382

oz (US liq)

cc (cm )

0.06102

cu. m

lit (liter)

2.1134

pt (US liq)

lit (liter)

1.057

qt (US liq)

lit (liter)

0.2642

gal (US liq)

kg/mm

56.0C7

lb/in

kg/cm

14.2234

psi (lb/in²)

INCH TO METRIC SYSTEM

KNOWN

MULTIPLIER

RESULT

ft-lb

0.13826

m-kg

in-lb

0.01152

m-kg

ft-lb

13.831

cm-kg

in-lb

1.1521

cm-kg

WT.

lb

0.4535

kg

oz

28.352

g

DISTANCE

mpg

0.4252

km/lit

mph

1.609

km/hr

mi

1.609

km

ft

0.3048

m

yd

0.9141

m

in

2.54

cm

in

25.4

mm

VOLUME /

CAPACITY

oz (US liq)

29.57

cc (cm )

cu.in

16.387

cc "cm )

pt (US liq)

0.4732

lit (liter)

qt (US liq)

0.9461

lit (liter)

gal (US liq)

3.785

lit (liter)

MISC.

lb/in

0.017855

kg/mm

psi (lb/in )

0.07031

kg/cm²

Fahrenheit (°C)

5/9(°F-32)

Centigrade (°F)

DEFINITION OF TERMS:

m-kg

=

Meter-kilogram(s) (usually torque)

9

=

Gram(s)

kg

=

Kilogram(s) (1,000 grams)

lit

=

Liter(s)

km/lit

=

Kilometer(s) per liter (fuel consumption)

cc

=

Cubic centimeter(s) (cm³) (volume or capacity)

kg/mm

=

Kilogram(s) per millimeter (usually spring compression rate)

kg/cm²

=

Kilogram(s) per square centimeter (pressure)

COLOR CODE

D₈:

Dark green

Br:

Brown

L/W :

Blue/White

Ch :

Chocolate

0 :

Orange

Br/W

Brown /White

B :

Black

L:

Blue

Y/G :

Yellow/Green

Y :

Yellow

P :

Pink

B/W :

Black/White

Lg:

Light green

L/B:

Blue/Black

W/G

White/Green

G :

Green

R/W

Red /White

W/R

White/Red

W :

White

R/Y

Red/Yellow

G/Y •

Green/Yellow

Sb:

Sky blue

L/Y:

Blue/Yellow

Y/R

Yellow/Red

R :

Red

L/G :

Blue/Green

Y/B :

Yellow/Black