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Yamaha XS1, XS1B, XS2, TX650 Tech Bulletins, Service Data, Brochures

Discussion in 'The Garage' started by TwoManyXS1Bs, Oct 1, 2013.

  1. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Collected early model data back in the early 2000's. Thought it would be handy to other forum members searching for early model info.
    You can look in my albums or use these links:

    Early model brochures - XS1, XS2, TX650, TX650a - Yamaha marketing

    XS1, XS1B, XS2, TX650 Service Data (Yamaha website, 2004)

    XS1, XS1B, XS2, TX650 Technical Bulletins (various sources and Yamaha website, 2004)

    The Technical Bulletins have been named according to this scheme:

    [​IMG]

    List of Technical Bulletins, 1970-1973:

    70-02-23_S231-01_OilPumpCheck.jpg
    70-02-24_S232-01_EngineWorkStand.jpg
    70-03-06_S230-01_SetupServiceProcedure.jpg
    70-03-06_S230-02_SetupServiceProcedure.jpg
    70-03-06_S230-03_SetupServiceProcedure.jpg
    70-06-30_S236-01_MiscServiceInstructions.jpg
    70-06-30_S236-02_MiscServiceInstructions.jpg
    70-07-01_S237-01_HeavyOutyVaIveSprings.jpg
    70-07-01_S237-02_HeavyDutyValveSprings.jpg
    70-07-13_S242-01_IntakePortBalanceTube.jpg
    70-08-18_S244-01_CountershaftSprocketRemoval.jpg
    70-08-18_S244-02_CountershaftSprocketRemoval.jpg
    70-09-04_S249-01_NGKSparkPlugs.jpg
    70-09-30_S246-01_Carburetors.jpg
    70-09-30_S246-02_EngineOilEngineLeaks.jpg
    70-10-02_P300-01_FramePegsBrakeKickstartChanges.jpg
    70-10-02_P300-02_FramePegsBrakeKickstarlChanges.jpg
    70-11-00_S253-03_MechanicalDifferences.jpg
    70-11-12_S254-01_FaultyCamshaft.jpg
    70-12-05_S257-01_IgnitionAdvanceStoppers.jpg
    71-01-15_S259-01_GearboxSpacing.jpg
    71-01-15_S259-02_GearboxSpacing.jpg
    71-01-15_S259-03_GearboxSpacing.jpg
    71-01-15_S259-04_GearboxSpacing.jpg
    71-01-29_S262-01_ExhaustPipeObstruction.jpg
    71-02-12_S264-01_YamahaSealants.jpg
    71-02-19_S267-01_IgnitionTimingChange.jpg
    71-04-09_S272-01_CrankInstallingTools.jpg
    71-04-09_S272-02_CrankInstallingTools.jpg
    71-04-09_S272-03_CrankInstallingTools.jpg
    71-07-16_P309-01_ReplacementCylinderSleeves.jpg
    71-07-26_S275-01_InstallingCylinderSleeve.jpg
    71-10-18_P313-01_PistonImprovement.jpg
    71-10-26_S283-02_ColorAndColorCode.jpg
    71-11-26_P315-06_PartsListsCorrections.jpg
    71-12-10_S285-01_PrimaryDriveGearLash.jpg
    71-12-10_S285-02_PrimaryDriveGearLash.jpg
    71-12-20_P320-06_PartsChanges-OilpumpAndBanjoBolt.jpg
    71-12-20_P320-07_PartsChanges-CrankshaftConnectingRodShims.jpg
    71-12-20_P320-08_PartsChanges-HandleBarFittings.jpg
    71-12-20_P320-09_PartsChanges-BreatherCover.jpg
    71-12-20_P320-10_PartsChanges-ThrottleCable.jpg
    71-12-20_P320-11_PartsChanges-MiscNotes.jpg
    71-12-20_P320-12_PartsChanges-CrankcaseGasket.jpg
    71-12-20_P320-14_PartsChanges-PilotLamp.jpg
    72-03-20_S288-01_ValveClearanceChange.jpg
    72-05-31_P329-01_DiscBracketBearingSpacerChange.jpg
    72-06-18_S290-01_InspectShiftCams.jpg
    72-06-18_S290-02_InspectShiftCams.jpg
    72-06-20_S292-01_ShopRepairFees.jpg
    72-07-20_S294-01_CarburetorChange.jpg
    72-08-14_P337-01_CaliperModification.jpg
    72-08-14_P343-01_CarbStarterShaft-DiscBrakeChange.jpg
    73-07-20_P386-01_ValveAndColletChanges.jpg
    73-07-20_P386-02_ValveAndColletChanges.jpg
    73-12-03_P398-A1_BronzeSwingarmBushings.jpg
     
  2. 650Skull

    650Skull SSSSSSSSSlither Top Contributor

    Good stuff.

    Always been curious about how Yamaha changed the compression ratios through the years. Dropped from 8.7 down to 8.1, (obvious as the tech file states), then upped it to 8.4, 8.5 then 8.7 again.
     
  3. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Dragged-out my older computers, found more Service Bulletins. Cleaned them up and overhauled the bulletins album, now has 56 Service Bulletins for the years 1970 thru 1973. Also updated post #1 using 650Skull's and gggGary's link tricks (album id #'s stayed the same, so any older links should still work).

    There's bound to be more out there. If you find any, please post any 1970-1973 bulletins that are not in the album.
    Also, if you find a bulletin that's significantly crisper/clearer, please post it.

    Also found about 30 bulletins for the years 1974 thru 1979. Will be putting them in a separate album, and start a new thread on those...
     
    Last edited: Jul 20, 2014
  4. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    2many you hereby receive my award of the order of the busted knuckle for services provided to the troops. No one should attempt work on an XS without spending the hour or two needed to read through those service bulletins. I found many of the issues that the board has worked through over the years right there officially from Yamaha! Thanks again!
     
  5. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Thankyew, thankyew! I shall proudly wear it alongside my Cross-eyed Cross...
     
  6. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Needed a place to post this table, so put it in here. It's the best I could come up with, pouring through old parts manuals and service/parts bulletins. There's an awful lot of early model changes that don't seem to have any supporting documentation (13 changes to heads???), and will probably remain as mysteries. Updates, changes, revisions happily encouraged.

    (Notes on the very early XS650s, derived from parts manuals and bulletins)

    1970 XS1- S650-000101 to S650-006686 = 6586 bikes
    1971 XS1B S650-007101 to S650-025383 = 18283 bikes (includes XS1F)
    1972 XS2- S650-100101 to S650-133900 = 33800 bikes
    1973 TX650 S650-200101 to S650-2?????
    1974 TX650A 447-000101 to 447-012250 = 12,150 bikes

    (Updated 10-21-2019)
    256 Engine change chronology by S650- serial number:

    1970 XS1 S650-
    000136 - Add metal chainguide over shiftshaft, discontinue plastic protective sleeve.
    001125 - Clutch worm now metal with nylon housing, new left engine cover, new right oil filter cover (o-ring changed to gasket).
    001235 - Transmission mainshaft needle bearing OD change, new rev-1 cases, reinforcing gussets added behind left rear cylinder stud.
    001587 - Camshaft Endcover change, advancer side.
    002487 - Change to front camchain tensioner bolt holes, new cylinder.
    002515 - Carburetor change, from W1 to E2 (see bulletin #246)
    003269 - Connecting Rod change, discontinue small-end needle bearings.
    003430 - New Cases rev-2, Gussets continue, longer left & right case cover screws.
    003629 - Carburetor change, from E2 to E3 (see bulletin #246)
    004130 - Oil Pump & sump screen change, from 4mm to 6mm rotor.
    005830 - Change to kickstart shaft (see bulletin #300).

    1971 XS1B/F S650-
    007344 - Added outer spring to intakes' balance tube.
    008244 - Change to kickstart shaft, needle bearing thrustwasher replaced with shims and circlip.
    009685 - Oil Breather change, from 1-pipe to 2- pipe (see bulletin #320).
    015654 - Head & Camcover change (now at rev-13).
    016844 - Camshaft Endcover change, points side, and gaskets.
    017968 - Tachometer drive change, separate screw adapter for tach cable now used.
    018608 - Camchain tensioner system change, from type 'A' to 'B'. (6-hole tensioner on 4-hole cylinder)
    022833 - New Cases rev-3, Gussets behind left rear cylinder stud removed, Front mount nose shortened, Oil pump change to 8mm rotor, revised banjo hole.
    023130 - Piston change, compression ratio changed from 8.7:1 to 8.1:1.

    1972 XS2 S650-
    To-be-done....EGADS!!!

    **********************************
    XS1/XS1B engine case evolution

    1970 XS1 S650-
    000101 - Rev-0 case, no reinforcing gussets behind left rear cylinder stud.
    001235 - Rev-1 case, Reinforcing gussets added, Transmission mainshaft needle bearing OD change.
    003430 - Rev-2 case, Gussets continued, longer left & right case cover screws.

    1971 XS1B/F S650-
    022833 - Rev-3 case, Gussets behind left rear cylinder stud discontinued, Front mount nose shortened.

    Rev-0 case.
    Early_XS1_Rev0_case.jpg

    Rev-1 case.
    Early_XS1_Rev1_CaseGussets.jpg

    Rev-2 case.
    Early_XS1B_Rev2_CaseGussets2.jpg

    The change to the front mount, Rev-3 cases, starting at S/N S650-022833

    FrontLeft-XS1B-XS2.jpg XS1B-FrontMount.jpg
     
    Last edited: Oct 21, 2019
    gggGary likes this.
  7. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    Was looking for a 72 SB on the front brakes pretty sure you posted it "somewhere" guess I'll keep looking. Thanks for all your hard work on these! What a great resource.
     
  8. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Hey, gggGary. These 3 entries, listed above, have some XS2 front brake info.


    72-05-31_P329-01_DiscBracketBearingSpacerChange.jpg

    72-08-14_P337-01_CaliperModification.jpg

    72-08-14_P343-01_CarbStarterShaft-DiscBrakeChange.jpg

    Is there more out there?
     
    gggGary likes this.
  9. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

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