Xj 700 service manual

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No shipping cost or waiting. Instant Download. Other information that might describe this product! Attach the u niversal Clutch Holder 2. NOTE: Identify each crankshaft bearing position very carefully so that it can be reinstalled in its original place.

Remove housing using Torx Driver 30 Use Armature Shock Puller and 3. NOTE: Identify each lifter and pad position very carefully so that it can be reinstalled in its original place. Measure the warpage using a precision straight edge or surface plate and feeler gauges. Resurface if warpage exceeds allowable limit. NOTE: Deburr any deformed valve stem end. Use an oil stone to smooth the stem end.

Install the camshaft case 1. Torque the camshaft case bolts to 10 Nm 1. Use a bore gauge 3 to determine the valve guide inside diameter. Valve Guide Inside Diameter Limit: 5. Measure the valve stem diameter with a micrometer. Replace guide if clearance exceeds specification. Intake 0. Examine the valve face for pitting or wear and regrind as necessary.

Measure the v alve face as indicated below and replace if valve cannot be brought back to specification. Minimum Thickness Service limit 1 : 0. Minimum Length Service limit 3 Replace if larger than rest or stem. Replace if it exceeds specification. Replace if excessive. Remove the valve guide. Use Valve Guide remover 1 Bore valve guide 1 to obtain proper valve stem clearance. Use 5. Cut new faces as required. Measure the valve seat width 1. Follow the next steps if out of specification.

Position the v alve into the cylinder head. Flush thoroughly as required. Spin it rapidly back and forth, then lift valve and clean off all grinding compound. Inspect the valve seat surface. Wherever valve seat and valve face made contact, blueing will have been removed.

Width 1 : 1. Position 2 : 0. NOTE: Cut valve seat using valve seat cutter 1 if valve seat width exceeds limit or if valve seat is pitted or worn. Apply c oarse lapping compound Small amount! Rotate the valve. Turn until valve and valve seat are evenly polished, then clean off compound. Repeat above steps with fine compound and continue lapping until valve face shows a completely smooth surface uniformly.

Apply m echanic's bluing dye Dykem 1 to valve face and seat. Rotate the v alve. Valve must make full seat contact indicated by grey surface all around valve face where bluing was removed.

Apply solvent into each intake and exhaust port. If solvent leaks past valve seat, relap until seal is complete. NOTE: Pour solvent into intake and exhaust ports only after completion of all valve work and assembly of head parts.

Measure the v alve spring free length. Replace if out of specification. Camshaft Cap Bolts: 10 Nm 1. Camshaft-to-cap Clearance: 0. Measure the camshaft bearing surface diameter 1. Use a micrometer. Standard: Check the o ne-way cam operation. Replace if operation is not smooth. Inspect: all parts for damage and wear. Replace as necessary. Replace worn sprockets. Inspect the c ylinder walls for vertical scratches and Rebore or Replace cylinder as required.

NOTE : Obtain measurements at three depths by placing measuring instrument parallel to and at right angles to crankshaft. Piston 1. Measure the piston skirt diameter " P " 2. NOTE: Measure the piston skirt diameter where the distance 1 is 5. NOTE: Clean carbon from piston ring grooves and rings before measuring side clearance.

NOTE: Insert a ring into cylinder, and push it approximately 2 0 mm 0. Push ring with piston crown so that ring will be at a right angle to cylinder bore. NOTE: You cannot measure end gap on expander spacer of oil control ring. If oil control ring rails show excessive gap, replace all three rings. Measure the crankshaft runout at main journal bearings.

Use a Dial Gauge Install connecting rod bearings 1 into connecting rod and cap. NOTE: Do not move connecting rod until a clearance measurement has been completed. Apply continuous torque between 2. Once you reach 2. If tightening is interrupted between 2. Connecting Rod Cap: 3 6 Nm 3. Replace connecting rod bearing if clearance is excessive. Connecting Rod Bearing Clearance: 0. Position u pper crankcase half. Place on a bench in an upside down position. NOTE: Do not move crankshaft until clearance measurement has been completed.

Remove b olts in reverse assembly order. Replace crankshaft if necessary. Main Bearing Oil Clearance: 0. The first five are main bearing journal numbers, starting with the left journal. The four rod bearing journal numbers follow in the same sequence. The numbers are stamped in ink on the rod cap 1. Example, Selection of the crankshaft main bearing: If the crankcase J1 and crankshaft J1 sizes are No.

Example 2 , Selection of the connecting rod bearing: If the connecting rod P1 and crankshaft P1 sizes are No. NOTE: The clutch boss contains a built-in damper beneath the first clutch friction plate clutch plate 1. It is not necessary to remove the wire circlip 2 and disassemble the built-in damper unless there is serious clutch chattering.

Inspect the c lutch boss spline 3 for pitting:. Place clutch plate on surface plane. For each plate: Use feeler gauge 1 to measure maximum warpage from surface. Measure Friction plate thickness. Friction Plate Thickness.

Clutch Spring Minimum Free Length 1 : Measure the t ransmission shaft runout. Use a centering device and dial gauge. Replace shaft if bent. Note: Minor rounding of the dogs can be corrected by undercutting. See the article on "Repairing second gear" elsewhere on this site. Inspect each b earing. Clean and lubricate, then rotate inner race with finger.

Inspect all o il seals. Replace any damaged or worn seals. Drive Axle Bearing Housing: 12 Nm 1. Shift Cam Locating Pin: 8 Nm 0. Install the crankshaft bearings See inspection for crankshaft bearing selection. Install the c onnecting rod bearings into connecting rod and cap. Lubricate the c onnecting rod bolt threads with Molybdenum Disulfide Grease. Drive Chain Guide: 8 Nm 0. Place the cam chain 1 , drive chain 2 , and oil seal 3 onto the crankshaft.

NOTE: Lightly apply grease to the oil seal lips. Do not apply sealant to within mm 0. Crankcase: 6 mm bolt: 12 Nm 1. NOTE: The embossed numbers in the crankcase designate the crankcase tightening sequence.

Oil Pan: 12 Nm 1. Note: The outermost friction plate has a V-cut in it. Give some identifying mark to the corresponding dog in the clutch housing. CAUTION: Be sure that the oil pump drive gear tabs engage the clutch housing grooves on its back or the tabs will be damaged when tightening the clutch boss securing nut.

If you forget to identify the position with a mark, measure the width of each dog. The other width are 14 mm 0. NOTE: Align a dot on the clutch boss with a dot on the pressure plate. Clutch Cover: 1 2 Nm 1. Water Pump Drive Gear: 12 Nm 1. Cover: 8Nm 0. Bearing Retainer: 25 Nm 2. Stake the screw heads to the dents on the bearing retainers with a center punch.

Middle Driven Gear Housing: 25 Nm 2. Crankcase Cover: 12 Nm 1. NOTE: Align the grooves on the stator coil core with the bolt holes on the crankcase. Cover: 12 Nm 1. NOTE: Align the locating pin on the crankshaft with the corresponding slot in the timing plate. Pickup Bolt: 8 Nm 0. NOTE: Be sure to install the rings so that Manufacturer's marks or numbers are located on the top side of the rings. Oil the pistons and rings liberally. Set p iston ring ends as per the above diagram.

Cam Chain Guide Rear : 1 0 Nm 1. Check gu ide movement. Reassemble if the action is not smooth. Set the dial gauge on the No. If not, loosen the pointer securing screw and adjust.

Tighten nuts in sequence as shown and torque the nut in two stages. Cylinder Head: [ 10 mm ] 37 Nm 3. Install the c am chain guide Front 1. NOTE: The lower end of chain guide must rest in the cam chain guide slot in the crankcase. Do not turn the crankshaft during the camshafts installation. Cam Cap: 10 Nm 1. Do not turn the crankshaft when installing the sprockets. NOTE: When installing the sprocket, use holes except for the one with a punch mark 4.

Tighten the bolt. Sprocket: 20 Nm 2. CAUTION: Be sure to attain the specified torque value to avoid the possibility of these bolts coming loose and causing damage to the engine. Apply engine oil to the cam chain, sprockets, camshafts, and valves.

Turn the crankshaft counterclockwise a few turns to ensure that it turns smoothly. Crankshaft End Cover Left : 7 Nm 0. Radiator Pipe : 8Nm 0. NOTE: The middle gear lash can be checked only when the gears are installed in the crankcase. NOTE: Before installing the tool, loosen the holder bolt all the way out and after installation tighten this bolt as tight as necessary finger tight is generally sufficient.

Attach a d ial gauge against the middle drive flange as shown. Measure m iddle gear lash by rotating the flange gently back and forth. Follow Gear Lash Adjustment procedure if lash is not within specified limits.

NOTE: Check this engagement at 4 points. If the gear lash exceeds the specified limit and adjustment is necessary, the engine or swing arm should be removed from the motorcycle. Install the driven gear housing assembly into the crankcase leaving about a 2 mm 0. Slowly tighten the bolts alternately until the dial gauge lash measurement reaches 0.

Measure the clearance between the bearing housing and the crankcase. This clearance is the shim size required. Install the p roper sized shim s 1. Recheck the m iddle gear lash. Readjust if necessary. NOTE: Middle drive gear and its shims can be removed without separating the engine. Use Damper Compressor 1 with hydraulic press 2. NOTE: Perform following steps only if middle-drive-shaft bearing or gear must be replaced.

If necessary, replace all middle gears as a set. Check bearing movement. Rotate the race by finger and replace if rough. Because shim can only be selected in 0. In above example, calculated shim thickness is 0. The chart instructs you, however, to round off the 8 to Thus you should use two 0.

Bend lock washer of nut into middle drive shaft slot using a center punch. Flange Holding Nut: 90 Nm 9. Refer to engine removal. Reverse those removal steps that apply. Engine Mounting Bolt: Front 1 : 42 Nm 4.

Install the Carburetors. Note: see Carburetor section for further details. Reservoir Tank Capacity: 0. The coolant is circulated by an impeller type pump mounted on the right-hand crankcase and driven by a gear. The coolant is drawn by the pump from the bottom tank of the radiator, through the pipe 1 , and discharged into the cylinder head and cylinder through the pipe 2.

The coolant passes from the cylinder head through coolant ways and after circulating around combustion chamber jacketing enters the radiator upper tank via inlet pipe 3.

The heated coolant from the engine then passes down through the finned tubes to the bottom tank of the radiator. These finned tubes present a large surface area to the air and dissipate the heat. Drain the coolant.

NOTE: Be sure to drain the coolant before disassembly of the cooling system components. Eliminate deposits from the impeller and water pump housing.

Water Pump Cover: 10 Nm 1. Water Pump Drive Gear: 12Nm 1. Disconnect e lectrical leads 2. Inspect o -ring 1 Replace if worn or damaged. Check t hermostatic valve and replace if out of specification. NOTE: Thermostat is sealed and its setting is specialized work. If its accuracy is in doubt, always replace it. A faulty unit could cause serious overheating or overcooling. NOTE: Install the thermostatic valve so that the breather hole is forward.

Install the t hermostat housing 1. Blow out obstructions with compressed air through rear of radiator. Straighten bent fins with a radiator comb. Replace if cracked or damaged. Valve Opening Pressure: kPa 0. Replace radiator cap if defective. Decrease of pressure indicates leaks in system. Locate and repair as required. Total Amount: 2. You may use boiled water or distilled water if no soft water is available. Install the r eservoir tank cap 3. NOTE: The carburetor bank can be used as a level.

Set petcock to "PRI" or use temporary fuel supply. Check that the fuel level of one carb against both left and right sides of bank is be equal. Fuel Level a : bottom of meniscus to bottom edge of the carburetor body 3. Never raise the hose while taking the measurements.

Raising the hose will make the measurement inaccurate. If the level slowly rises, the float needle valve is leaking and must be polished or replaced. NOTE: It's easy to lose track of the carb s once you flip them upside down to make that float tang adjustment. Marking the 1 carb with a piece of tape will help keep them identified.

Remove carburetor assembly. Refer to engine removal section. NOTE: The following parts can be cleaned and inspected without disassembly.

Number each carburetor before removing it from carburetor brackets. NOTE: When separating the carburetors be sure not to lose the small spring 4 that may fall out.

This spring connects the throttle levers. NOTE: Remove the needle jet toward the vacuum piston. Inspect the starter plunger 1 for damage. Replace if damaged or worn. Replace if torn or damaged. Do not use any caustic carburetor cleaning solutions. If necessary, use a single bristle from a stiff nylon brush.

NOTE: To assemble the carburetors, reverse the disassembly procedures. Pay close attention to the installation of the vacuum piston diaphragm and the location of each jet. NOTE: The float should be just resting on, but not depressing, the spring loaded inlet needle. NOTE: Float height is an approximation of fuel level. For best results, fine tune fuel level. See Fuel Level Adjustments.

A Technique for reinstalling old hardened intake boots. Note: This will probably not work on other models with long boots. This is not a Yamaha procedure. It was developed by Joe D. HAP and dv. Step 1. After soaking the rubber in a bucket of hot water, secure each air box boot to the carburetor with it's clamp.

Step 2. Slide the carbs in from the right hand side above the rubber intake manifolds on the engine and below the frame.

The free end of the boot is usually much more flexible than the end that has been attached to a hot carburetor for 20 years and will flex. Take care not to pull the boots off the carbs, especially when easing 4 around the clutch cable. This is far easier to accomplish with at least two people.

Step 3, Once the carburetors are aligned with their respective intake manifolds, ease the air box boots into their holes. There are two lips that normally sit on either side of the airbox wall. Ignore them for now.

Step 4. Pull back on the carbs enough to gain clearance between the front and the manifolds. Rotate the front of the carbs down into position. Carefully examine all around each one to ensure the rubber has not folded in front of the carb. Use a hooked too: to pull any folds out as required. Step 5, Push the carburetors forward into the manifolds.

They will snap into place as the lip engages the groove on the carburetor. Secure with clamps. Massage the airbox boots into place with a long straight screwdriver. Now is the time to ensure the sealing lips are properly positioned with one lip on either side of the airbox. Throttle Cable Free Play a : 2- 5 mm 0. Place the motorcycle on its centerstand and a garage jack under the engine.

NOTE: Do not depress the brake lever when the wheel is off the motorcycle otherwise the brake pads will be forced shut. NOTE: Lower the wheel until the discs come off the calipers.

Turn the calipers outward so they do not obstruct the wheel. Roll the axle on a flat surface 1. Replace if it is bent.

Radial 2 : 2 mm 0. Wheel is not statically balanced if it comes to rest at the same point after several light rotations. Install appropriate balance weight at lightest point on top.

NOTE: Balance wheel with brake disc installed. Failure to do so may cause an accident resulting in motorcycle damage and possible operator injury. Use soft metal drift punch and hammer. The spacer 1 "floats" between bearings.

Remove both bearings as described. Use a socket or bearing press 2 that matches outside diameter of bearing outer race to drive in bearing. Contact should be made only with the outer race. Install Front wheel. Reverse removal procedure. Use lightweight, lithium base grease.

Move the wheel towards the right side to separate it from final gear case. Measure the thickness of the b rake shoes. Use slide calipers. Inspect brake shoes. Sand glazed pads with coarse sandpaper. Inspect b rake drum inner surface. Wipe any oil off brake drum with rag soaked in lacquer thinner, brake parts cleaner or other solvent. Polish any scratches from brake drum lightly and evenly with emery cloth. Inspect c am face. Replace if worn. Grease camshaft before reassembly. Place alignment marks 1 on the cam lever and camshaft when assembly.

Axle Nut: Nm Adjust r ear brake free play. Turn adjuster 1 as needed. Use only clean brake fluid. It is not necessary to disassemble brake caliper and brake hose to replace brake pads. Remove c aliper piston assembly. Use compressed air and proceed carefully. NOTE: Be sure to reinstall the larger diameter lips of the cylinder cups first.

Inspect the c aliper piston assembly. Replace if there are scratches or other damage. Replace the brake pads as a set if worn below wear limits 1.

Inspect m aster cylinder body and caliper body. Replace if scratched. Clean all passages with new brake fluid. Replace brake hoses if cracked, frayed, damaged or over 4 years old. Maximum Deflection: 0. Tighten the c aliper securing bolts 1 and brake hose union bolt 2. Union Bolt 1 : 26 Nm 2. Air bleeding steps: a. Add proper brake fluid to the reservoir. Install diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. Connect the clear plastic tube 1 4.

Place the other end of the tube into a container. Slowly apply the brake lever several times. Pull the lever in. Hold the lever in position. Loosen the bleed screw and allow the lever to travel towards its limit.

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