Yamaha XJ - Cylinder Block Inspection; Cylinder Block Installation

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Contents2
Identification Numbers4
Identifying Model Years4
Buying Parts5
General Specifications5
Maintenance Techniques, Tools and Working Facilities6
Fastening Systems6
Tightening Sequences and Procedures6
Gasket Sealing Surfaces6
Maintenance and Minor Repair Tool Kit10
Repair and Overhaul Tool Set10
Special Tools10
Care and Maintenance of Tools10
Working Facilities11
Safety First12
Essential Dos and Don'ts12
Asbestos12
Fire12
Motorcycle Chemicals and Lubricants13
Troubleshooting14
Engine Doesn't Start or Is Difficult to Start15
Starter Motor Does Not Rotate15
Starter Motor Rotates but Engine Does Not Turn over15
No Fuel Flow15
Poor Running at Low Speed16
Stalls after Starting16
Rough Idle16
Spark Weak16
Poor Running or no Power at High Speed17
Overheating17
Firing Incorrect17
Fuel/Air Mixture Incorrect17
Clutch Problems18
Compression too High18
Engine Load Excessive18
Clutch Slipping18
Gear Shifting Problems19
Abnormal Engine Noise19
Abnormal Driveline Noise19
Valve Noise19
Abnormal Frame and Suspension Noise20
Oil Level Indicator Light Comes on20
Excessive Exhaust Smoke20
Brake Noise20
Poor Handling or Stability21
Braking Problems21
Electrical Problems21
Handlebar Hard to Turn21
Battery Overcharged22
Tune-Up and Routine Maintenance23
Specifications24
Recommended Lubricants and Fluids25
Yamaha FJ, FZ, XJ, YX Radian 600 Routine Maintenance Intervals26
Daily or before Riding26
After the Initial 500 Miles26
Every 500 Miles26
Introduction to Tune-Up and Routine Maintenance27
Fluid Levels - Check27
Engine Oil27
Battery Electrolyte Level/Specific Gravity - Check28
Brake Fluid28
Brake Pads - Check30
Brake Shoes - Check30
Brake System - General Check30
Brake Lever Play and Pedal Position - Check and Adjustment31
Front Brake31
Rear Brake31
Drum Brake Models31
Tires/Wheels - General Check32
Throttle Operation/Grip Freeplay - Check and Adjustment32
Throttle Check32
Throttle Cable Adjustment32
Clutch - Check33
Drive Chain and Sprockets - Check, Adjustment and Lubrication33
Engine Oil/Filter - Change35
Lubrication35
Air Filter Element - Servicing36
Cylinder Compression - Check37
Spark Plugs - Replacement37
Lubrication - General38
Valve Clearances - Check and Adjustment40
Early Models41
Later Models41
All Models42
With Yamaha Valve Adjusting Tool42
With Universal Valve Adjusting Tool43
Idle Speed - Check and Adjustment44
Carburetor Synchronization - Check and Adjustment44
Intake Valve Shim Selection Chart44
Exhaust Valve Shim Selection Chart45
Evaporative Emission Control System - Check46
Exhaust System - Check46
Steering Head Bearings - Check, Adjustment and Lubrication46
Fasteners - Check48
Fuel System - Check and Filter Cleaning48
Suspension - Check48
Fork Oil - Replacement49
Cam Chain Adjustment50
Engine, Clutch and Transmission51
General Information55
Operations Possible with the Engine in the Frame55
Operations Requiring Engine Removal55
Engine - Removal and Installation55
Engine Disassembly and Reassembly - General Information57
Valve Cover - Removal and Installation58
Camshaft Chain Tensioner - Removal and Installation58
Camshafts, Valves and Chain Tensioner - Exploded View60
Camshafts Removal61
Camshafts Inspection62
Camshafts Installation64
Valve Lifters Removal65
Valve Listers Inspection65
Valve Listers Installation65
Cylinder Head Removal65
Cylinder Head - Exploded View66
Cylinder Head Installation68
Valves/Valve Seats/Valve Guides - Servicing68
Cylinder Head and Valves Disassembly68
Cylinder Head and Valves Inspection69
Cylinder Head and Valves Reassembly71
Cylinder Block Removal72
Cylinder Block Inspection73
Cylinder Block Installation73
Cylinder Block Details74
Pistons Removal75
Pistons Inspection76
Pistons Installation77
Piston Rings - Installation77
Oil Pan and Relief Valves - Removal78
Relief Valve Inspection78
Relief Valve Installation80
Oil Pump Pressure Check80
Oil Pump Removal81
Oil Pump Exploded View81
Oil Pump Inspection82
Oil Pump Installation82
Oil Cooler and Hoses - Removal and Installation82
Clutch Removal83
Oil Cooler Details83
Clutch Inspection84
Clutch - Exploded View84
Clutch Installation85
Clutch Cable - Removal87
External Shift Mechanism88
Shift Linkage and Pedal88
Shift Mechanism Removal88
External Shift Linkage - Exploded View88
Shift Mechanism Inspection89
Shift Mechanism Installation89
Crankcase Disassembly90
Lower Crankcase - Exploded View90
Crankcase Reassembly91
Upper Crankcase - Exploded View91
Crankcase Components - Inspection and Servicing92
Main and Connecting Rod Bearings - General Note92
Crankshaft and Connecting Rod Details93
Crankshaft Removal94
Crankshaft Inspection94
Crankshaft Main Bearing Selection94
Crankshaft Installation95
Connecting Rods and Bearings - Removal96
Connecting Rods and Bearings Inspection97
Connecting Rod Bearing Selection97
Connecting Rods and Bearings Installation98
Starter Chain and Camshaft Chain Removal98
Chain Guides98
Starter Chain and Camshaft Chain Inspection99
Chain Guides Installation99
Transmission Shafts Removal99
Transmission Shafts Installation99
Mainshaft Disassembly100
Transmission Gears and Shafts - Exploded View100
Mainshaft Inspection101
Mainshaft Reassembly102
Driveshaft Disassembly102
Driveshaft Inspection103
Driveshaft Reassembly103
Shift Cam and Forks Removal103
Shift Cam and Forks Inspection103
Shift Cam and Forks Installation104
Starter Clutch and Drive Chain Tensioner Removal104
Starter Clutch and Drive Chain Tensioner Disassembly, Inspection and Reassembly105
Starter Clutch and Drive Chain Tensioner Installation105
Initial Start-Up after Overhaul105
Recommended Break-In Procedure106
Fuel and Exhaust Systems107
Fuel Tank - Removal and Installation109
Fuel Tank - Cleaning and Repair109
Idle Fuel/Air Mixture Adjustment - General Information109
Carburetor Overhaul - General Information110
Carburetors - Removal and Installation110
Carburetors - Disassembly, Cleaning and Inspection111
Carburetors Exploded View112
Carburetors - Separation and Joining118
Carburetors Float Height Adjustment119
Carburetors Fuel Level Adjustment119
Throttle Cable and Grip Removal119
Throttle Cable and Grip Installation120
Throttle Cable and Grip Adjustment120
Choke Cable Removal120
Choke Cable Installation120
Exhaust System Exploded Views121
Ignition System123
Ignition System General Information124
Ignition System Check124
Engine will Not Start124
Engine Starts but Misfires124
Ignition Coils Check125
Ignition Coils Removal and Installation125
Pickup Coils Check125
Pickup Coils Removal126
Pickup Coils Installation126
Igniter Check126
Igniter Removal and Installation126
Frame, Suspension and Final Drive127
Frame, Suspension and Final Drive General Information128
Frame - Inspection and Repair128
Side and Centerstand - Maintenance128
Handlebars - Removal and Installation129
Front Forks - Removal130
Front Forks - Installation130
Forks Disassembly130
Front Forks Exploded Views131
Forks Inspection134
Forks Reassembly135
Steering Head Bearings - Replacement135
Steering Head Bearings Removal135
Steering Head Bearings Inspection139
Steering Head Bearings Installation139
Rear Shock Absorber Removal139
Rear Shock Absorber Inspection140
Rear Shock Absorber Installation142
Rear Suspension Linkage - Removal, Inspection and Installation143
Rear Suspension Linkage and Swingarm Details143
Swingarm Bearings - Check144
Swingarm Details144
Swingarm - Removal and Installation145
Swingarm Bearings - Inspection and Replacement145
Drive Chain Removal146
Drive Chain Cleaning146
Drive Chain Installation146
Sprockets - Check and Replacement146
Rear Wheel Coupling/Rubber Damper - Check and Replacement147
Suspension Adjustments147
Brakes, Wheels and Tires149
Rear Caliper Exploded View150
Rear Calipers150
Brake Caliper Removal151
Rear Brake Caliper Exploded View151
Brake Caliper Overhaul152
Brake Caliper Installation153
Brake Discs Removal153
Brake Discs Inspection153
Brake Discs Installation153
Front Brake Master Cylinder Removal154
Front Brake Master Cylinder Overhaul154
Front Brake Master Cylinder - Exploded View154
Front Brake Master Cylinder Installation155
Rear Brake Master Cylinder Removal156
Rear Brake Master Cylinder Overhaul156
Rear Brake Master Cylinder Exploded View156
Front Brake Hose Details157
Rear Brake Master Cylinder Installation157
Brake Hoses Inspection157
Brake Hoses Replacement158
Brake System Bleeding158
Rear Drum Brakes Removal159
Rear Drum Brakes Inspection159
Rear Drum Brakes Installation159
Wheels Inspection and Repair160
Wheels Alignment Check160
Front Wheel Removal161
Front Wheel Installation161
Front Wheel Details161
Rear Wheel Details162
Rear Wheel Removal163
Rear Wheel Installation164
Wheel Bearings - Inspection and Maintenance165
Front Wheel Bearings165
Tubeless Tires - General Information166
Rear Coupling Bearing166
Rear Wheel Bearings166
Tire Changing Sequence - Tubeless Tires167
Fairings and Bodywork168
Seat Removal and Installation168
Side Covers Removal and Installation169
Lower Fairing Removal and Installation169
Upper Fairing Removal and Installation170
Lower and Center Fairings Removal and Installation170
Electrical System171
Electrical System General Information173
Electrical Troubleshooting173
Battery Inspection and Maintenance173
Battery Charging173
Fuses - Check and Replacement174
Lighting System Check174
Headlight174
Taillight/License Plate Light174
Headlight Bulb - Replacement175
Brake Light175
Neutral Indicator Light175
Oil Level Warning Light175
Headlight Aim - Check and Adjustment176
Turn Signal and Taillight Bulbs Replacement177
Turn Signal Circuit - Check178
Brake Light Switches - Check and Replacement178
Circuit Check178
Switch Replacement178
Electrical Component Locations179
Instruments and Speedometer Cable Removal and Installation180
Rear Brake Pedal Switch180
Meters and Gauges Check181
Instrument and Warning Light Bulbs Replacement181
Tachometer and Speedometer181
Oil Level Sender Removal182
Oil Level Sender Check182
Oil Level Sender Installation182
Ignition Main (Key) Switch Check and Replacement182
Handlebar Switches Check183
Handlebar Switches Removal and Installation183
Neutral Switch Check and Replacement184
Sidestand Switch Check and Replacement184
Clutch Switch Check and Replacement184
Horn Check185
Horn Replacement185
Starter Relay Check185
Starter Relay Replacement185
Starter Motor Installation186
Starter Motor Disassembly186
Starter Exploded View187
Starter Motor Inspection188
Starter Motor Reassembly189
Charging System Testing - General Information and Precautions190
Charging System - Output Test190
Charging System - Component Tests190
Alternator - Removal and Installation191
Regulator/Rectifier Removal and Installation192
Wiring Diagrams193
Color Code195
Conversion Factors196
Index197

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Yamaha XJ - Cylinder Block Inspection; Cylinder Block Installation

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