Question about 1978 Yamaha XS 650 E

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Exploded diagram of 1978 xs650 top end absent from my cd manual

How does the rear cam chain tensioner blade fix at the top?a small metal cage has posible been miss fitted

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G'day mate. It doesnt fix at the top, it is hinged from the bottom and need to be able to float free correct adjusted by the cam chain tensioner against the cam chain to to work correctly. Is there a reason you are worried about this? regards robotek

Posted on May 08, 2010

  • Graeme Ross
    Graeme Ross May 15, 2010

    Thought this may be helpful to you also. You can get(for free) a download of the service manual from here to help you see how it works. Hard to get the cam chain and tensioner wrong really. If you have the engine running,is the chain noisy? Do you have any end float in the cam shaft? the camshaft bearings need to be tight up against the first lobe of the cam, both sides, and the cam centralised.


    You can generally see where the bearings have been sitting in the past and use as an indicator to assist with lining things up. Happy to talk to you more about it.


    regards
    robotek

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My chain snapped and I fixed that. But exactly how is the chain threaded through the Shimano rear derailleur? What is the correct path over and under the 2 jockey wheels? I cannot find a diagram that shows...


It will entail taking the chain apart again (known as "breaking" the chain).
The chain feeds UNDER the lower cog on the derailleur, BETWEEN the 2 cogs, and OVER the top one... then BEHIND the gear cluster and back OVER it. Run the other end AROUND the front chainwheels, through the front derailleur and re-connect. You may find it helpful to lay the bike on its side (sprockets up) and have someone hold rear derailleur to keep tension off the chain.e86da85.jpg
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I have shimano rd6500 rear derailleurs. when chain is on small chain-ring and smaller rear sprockets the derailleur cage is rubbing against the chain.How do i tension chain to hold cage away from chain,...


If you learn to shift correctly this won't happen..

Google bicycle shifting technique, for example:

http://coachlevi.com/cycling/complete-beginner-guide-to-bicycle-gears-shifting/

You should NEVER run cross-chained (big-big or small-small). The drive train performs best when the chainline is as close to straight as possible. Excess sideways stress on the chain will wear it out prematurely and increase its normal efficiency.

To demonstrate this for yourself, put the bike in the same combination of gears you're having a problem with. Get behind the bike and look staright along the top of the chain. As you can see the line of the chain is a mild zig-zag where it is parallel to the bike at each gear but needs to angle across the drivetrain in between. On some bikes the chain might even come in contact with the next larger chainring when used this way.


If you can shift to the big-big combination without snapping the rear derailleur off, you're lucky. The big-big combo uses up all available chain length and the rear derailleur will be pulled toward the front of the bike, sometimes so far that it is in danger of being snapped off.

THERE IS NO UPSIDE TO CROSS-CHAINING.

As you can see, the rear derailleur is not long enough to **** up all the slack this gear combination creates. There are other combinations that would yield the equivalent gear ratio without either stressing the drivetrain or dropping the chain.

The basics of shifting are these:
1) The big ring and right side of the cassette in back are for speed.
2) The small ring and the left side of the cassette are for high torque, lower speed

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Judging by your previous questions,I think this is the info you need.
Setting cam timing with stock cams is relatively easy using the punch mark on the cam gears For stock timing, the punch marks at 9 O'clock on the exhaust cam and at 3 O'clock on the intake cam should align with the top of the head. If stock timing is altered the exhaust cam punch mark will either be one tooth above or one tooth below the top of the head.
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  1. Take out tensioner.
  2. Remove both plugs from shifter side of crankcase, the center plug to turn, the 11:00 plug to locate the 'I' (not the H) in.
  3. Use a ratchet on end of crankshaft (through center plug) and zip tie ratchet to footpeg with the I lined up in the timing plug hole.
  4. With the intake cam (rear one) pointing straight back, align the punch mark on the backside of the intake cam sprocket with the top of the head. Since the slack in the timing chain is in the back, if it doesn't align exactly right at the top of the head, err slightly high. Zip tie chain to intake sprocket.
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  1. Remove exhaust cam, count 12 links (where sprocket teeth will go) from the punch mark on the top of the intake cam and mark that position on the chain with something noticeable (use a Sharpie). Hold the exhaust cam close the to intake cam with the exhaust cams pointing horizontally to the front of the bike. With the exhaust cam in this position, there will be a punch mark at the top. Put the tooth above this punch mark in the chain link you marked that was 12 or 13 over. Zip-tie the chain to the exhaust cam.
  2. Reseat exhaust cam. The punch mark on the left side of the exhaust sprocket will align with the top of the head. It will be one link high. Go back and check that the I is still centered in the timing plug hole
    1. the intake cams point back
    2. the exhaust cams point frontward
    3. the rear punch mark on the intake is aligned or slight high with the top of the head
    4. the front punch mark of the exhaust sprocket is aligned with the top of the head
  3. Bolt and torque exhaust cam, torque intake if you've had it off.
  4. Install chain tensioner (wind it up, hold the screwdriver with two hands, use the third hand to put hold tensioner in place, and fourth hand to bolt it up, then release screwdriver and put end bolt in it.
  5. Remove zip ties on intake sprocket, exhaust sprocket, and ratchet holding TDC. Remove ratchet and replace both plugs.
  6. Put on valve cover and two hoses, reinstall tank and seat and go riding.

Please rate this a Fixya.

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