Opinions?

I have one running well xj650 maxim, and one torn to bits xj650 maxim. Now that I have the motor of the one torn down all the way to troubleshoot it not shifting higher than neutral, it seems to be an insurmountable project.

I have all the gears out of the bottom end. About 1/4 pound of fragmented plastic, aluminum and other FOD came out when i split the cases. I found this was the center cam chain guide under the valve cover. Easy fix, right? (I have all the timing guide parts on hand for the r2 (remove/replace).

My biggest issue is getting the case halves back together. I tried to dry run it once a couple months ago following the Haynes Manual, but I must be missing something. The gears all line up, but it seems impossible to get the shift forks to all line back up....

Do you think the Yamaha dealer would even take on a project like this? Give them all the parts and say, call me when it's running with a bill? Should I just keep this maxim torn down as a parts bin?

Thanks everyone.

 

I don't have the answer, as that's a bit deeper than I've torn into mine, but I gotta say not to take it to a dealer as yet. With the knowledge of the guys on the forum, you should be able to get things taken care of yourself without having to cough up an arm and a leg.

 

I find that using a gob o thick wheel bearing grease helps hold shift forks in position long enough for me to move like the wind to get the case halfs together. I haven't had a 650 apart so I have no idea how similar it is to the xj1100 engine.

 

Stop. No dealer, they will either laugh at you or rob you and then laugh. Do you have a factory book? If not, since you apparently do have the time, sit back and scrounge up a FACTORY book off eBay. They pop up all the time and it is 110% worth it trust me. I was struggling with a Clymer (I understand Haynes is better, but...) the factory book is light years above both of those. It honestly should go right together (with the possible aid of some HEAVY assembly lube...) If your choices are figure it out or call it a bucket of parts, I'd keep trying to get it together just for the learning experience. What do you have to lose?

 

i havent had the xj bottom end apart, but i tear down atv and dirtbike trannies all the time.

the first time i was putting one back together, i had the same issue as you. i cant explain it, but once you find the magic places to hold everything it will all slide together.

dont take it to the dealer, you got yourself in over your head wich is the best way to learn!!! quite often i will need an extra pair of hands to hold forks and dogs into place while another extra set of hands slides the cases together. you may need to recruit some friends.

when the halves are finally slipped together, dont bolt it up all the way! make sure everything turns and all that jazz. you'd hate to find out something is screwed up after its completely assembled.

youll get it, keep at it!