Chapter 1, INTRODUCTION

Submitted by xjcdadmin on Thu, 09/20/2018 - 08:37

YAMAHA XJ700N/NC

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number (1) is stamped into the right side of the steering head pipe.

NOTE:
The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your province or state.

Vehicle Identification Number: 
XJ700N (Except for California): JYA1FG00*EA000101 
XJ700NC (For California): JYA1JJ00*EA000101

ENGINE SERIAL NUMBER

The engine serial number (1) is stamped into the elevated part of the left rear section of the engine.

NOTE:

The first three digits of these numbers are for model identifications; the remaining digits are the unit production number.

Starting Serial Number: XJ700N (Except for California)

............... 1FJ-000101

XJ700NC (For California)

............... 1JJ-000101

NOTE:
Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS

1.      All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and 0-rings must be cleaned.

2.      Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates (f, and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) (1) and oil seal(s) (2) with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip (1), make sure that the sharp-edged corner (2) is positioned opposite to the thrust (3) it receives. See the sectional view. (4) Shaft

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques.

FOR TUNE UP

1. Inductive Tachometer P/N YU-08036

This tool is needed for detecting engine rpm.

2. Inductive Timing Light P/N YM-33277

This tool is necessary for checking ignition timing.

3. Compression Gauge P/N YU-33223

This gauge is used to measure the engine compression.

4. Y.I.CS. ShutoffTool P/N. YM-08025

This tool is needed to measure the carburetor fuel level.

5. Vacuum gauge P/N, YU-08030

This gauge is needed for carburetor synchronization.

6. Fuel level gauge P/N. YM-01312

This tool is needed to measure the carburetor fuel level.

FOR ENGINE SERVICE

1. Tappet adjusting tool P/N. YM-01245

This tool is necessary to replace valve adjusting pads.

2. Universal Clutch Holder P/N.YM-91042

This tool is used to hold the clutch when removing or installing the clutch boss lock nut.

3. Valve spring compressor P/N. YM-04019

This tool must be used for removing and installing the valve assemblies.

4. Valve guide remover P/N. YM-01225

This must be used to remove the valve guides.

5. Valve guide installer P/N. YM-04017

This tool is needed for proper installation of the valve guides.

6. Valve guide reamer P/N. YM-01227

This must be used when replacing the valve guide.

7. Valve seat cutter P/N. YM-91043

This tool is needed to re-surface the valve seat.

8. Rotor holding tool P/N. YM-04043

This tool is used to hold the A.C. Generator rotor during removal and installation.

9. Rotor puller P/N. YM-01080

This tool is needed to remove the A.C. Generator.

10. Rotor puller attachment P/N. YM-04052

This tool is needed when removing the A.C. Generator rotor together with the rotor puller.

11. Piston ring compressor P/N. YM-04044

This is used to compress piston rings when installing the cylinder.

12. Piston base P/N. YM-01067

Use 4 of these to hold the pistons during cylinder installation.

FOR SHAFT DRIVE SERVICE

1. Middle drive pinion holder P/N. YM-33222

This tool is needed when measuring gear lash.

2. Dial Gauge P/N. YU-03097

This gauge is used to measure gear lash.

3. Damper Spring Compressor P/N. YM-33286

This tool is needed to disassemble and reassemble the middle gear damper.

4. Middle-Drive-Shaft-Bearing-Retainer Wrench P/N. YM-04057

This tool is used to loosen or tighten the bearing retainer.

5. Final Gear Holding Tool P/N. YM-01254

This tool is needed when measuring gear lash.

6. Final-Drive Gear Lash Measurement Tool P/N. YM-01230

This tool is used to measure gear lash.

7. Middle and Final Gear Holding Tool P/N.YM-01229

This tool is used when measuring gear lash.

8. Final Drive Shaft Bearing Retainer Wrench P/N. YM-40450

This tool is used to remove and install the bearing retainer.

FOR CHASSIS SERVICE

1. T-Handle P/N. YM-01326— (1) Fork Damper Rod Holder P/N. YM-33298—(2)

These tools are used to loosen and tighten the front fork cylinder holding bolt.

2. Ring Nut Wrench P/N. YU-01268 — (1) YU-33975 — (2)

These tools are used to loosen and tighten the steering ring nut.

3. Front Fork Seal Driver (weight) P/N. YM-33963 — (1) Adapter (38 mm) P/N. YM-01372 —(2)

These tools are used when installing the fork seat.

4. Front Fork Cap Socket (17 mm) P/N. YM-01104

This tool is used when removing the cap bolt.

FOR ELECTRICAL COMPONENTS

1. Pocket Tester P/N.YU-03112

This instrument is invaluable for electrical system inspection and adjustment.

2. Electro Tester P/N.YU-33260

This instrument is necessary for ignition system inspection.