650G (Maxim)

Cleaning the Hitachi Carb

This series assumes you took the carbs apart, and are trying to figure out how to put them back together again. If you haven’t taken them apart yet, it’s a good idea to skim through this first anyway. Address any questions to: xj-owners@micapeak.com, and we’ll try to talk you through it.

 

Pictures and text by Dwayne Verhey

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Middle Gear Damper

MIDDLE GEAR/DAMPER

Transmission

 

TRANSMISSION

Rear Wheel

REAR WHEEL

Wiring Diagram

XJ650J WIRING DIAGRAM

COLOR CODE

Dg

Dark green

Br

Cylinder Head Removal

ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in order to remove the cylinder head, cylinder, or pistons.

A . Preparation for Removal

1 All dirt, mud, dust and foreign material should be thoroughly removed from the exterior of the engine before removal and disassembly. This will help prevent any harmful foreign material from getting into the engine oil.

Lower Crankcase Reassembly

2. Lower crankcase

a.   Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.

b.   Install the neutral switch.

c. Install the transmission drive axle assembly into the crankcase.

Cylinder and Cylinder Head Disassembly

13. Remove the front cylinder holding nut and remove the cylinder assembly. It may be necessary to tap the cylinder lightly to loosen it from the base gasket.

14. Remove the rear cam chain guide by loosening the holding bolt.

1. Holding bolt 2. Rear cam chain guide

Wheels and Brakes

CHAPTER 5. CHASSIS

 

FRONT WHEEL

A. Removal

1.    Place the motorcycle on the center stand.

2.    Remove the cotter pin and wheel axle

3. Remove the speedometer cable holder securing bolt.

Torque Values

Tightening torque 
(Unit: m-kg)

Part to be tightened

Part name

Thread size

Q'ty