Information from the service manual
P. Middle Gear
1. Damper disassembly
NOTE:
Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.
C. Piston
1. Mark each piston to aid in reassembly.
2. Place a clean towel or rag into the crank-case to keep circlips and material from falling into the engine.
3. Remove piston pin clips, piston pins, and pistons.
D. Pick-up Coil Assembly
A. Cable maintenance
NOTE:
See Maintenance and Lubrication intervals charts. Cable maintenance is primarily concerned with preventing deterioration through rust and weathering and providing proper lubrication to allow the cable to move freely within its housing. Cable removal is straight forward and uncomplicated. Removal will not be discussed within this section.
Applies to
1985/86 Yamaha XJ700X / XJ750X Maxim-X
1985/86 Yamaha XJ700 Maxim
----- 3-PART BRAKE LINE GUIDE ------
|
Upper Brake Line |
Quantity |
Here's a repost of a method I used quite successfully. There's no dangerous chemicals to spill; a consideration for me since I: a) live on a lake, and b) drink from a well. There's also no ball bearings or nuts to recover afterwards. You need a 10 amp battery charger, duct tape, a box of salt, water, a funnel, a piece of steel rod, electrical tape, methyl hydrate and light oil. I adapted it from a technique used by antique outboard restorers:
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.
ENGINE OVERHAUL
A. Cylinder Head and Cylinder
1. Remove the cylinder head cover.
2. Remove the left crankcase cover (pickup coil cover).
3. Remove the cam chain tensioner.
5. Clutch assembly
a. Install the thrust plate onto the transmission main axle.
1. Thrust plate
b. Install the oil pump drive sprocket onto the main axle without the spacer collar and place the oil pump drive chain on its sprocket.
1. Oil pump drive sprocket
C. Middle Gear Servicing
1. Disassembly
Refer to page 39 for disassembly.
2. Inspection
Refer to page 52 for inspection.
3. Gear lash check
NOTE:---------------------------------------------------
11. Pistons and Cylinder a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.
NOTE:--------------------------------------------------------
Before installing the piston pin clips, cover
the crankcase with a clean rag so you will
not accidentally drop the circlip into the
crankcase.