Rear Wheel Assembly

Hi guys, we have a problem with the rear wheel for a XJ650 from 1980. It is originally sold in Japan and was called Yamaha XJ650 Special.

We have taken the whole bike apart, painted the frame, changing bearings in both wheels, new bearings, o-rings, oilseals etc in the engine (almost 2000 US in parts).

Try to get the rear wheel back and it get stuck far away from the 77 nm that is stated in Service Manual.
First we thought it was the dustcover (21) and it was making marks inside. But even without the dustcover the wheel got stuck with almost no torque.

According to the picture http://www.yamahapartshouse.net/pages/O ... MOTORCYCLE)/REAR_WHEEL_(XJ650G_-_1980)
we have the axle (23) and the collar (27) on the right side (collar outside the brakedrum) and then nothing except the washer and the special nut on the left side.
Inside we replaced the 3 bearings with original Yamaha parts with the right numbers. The spacer (2) and the flange (3) are there.
We actually took 2 XJ650 apart (1980 and 1981) and we have messed it up a little here and there keeping the different parts apart. But we tried the other wheel that we have not changed bearings in and we got the same problem.
And looking in EBAY where someone sold a complete rear axle there were the axle, the nut and 3 different washers, collars (not 2 that we are trying with).

So my question, Have we missed something, should it be another washer-collar somewhere? Cannot find that in the partslist, not in Haynes and not in Yamaha Service manual.

So if someone got an advice or the cause of the problem, we would be very happy.
We are 3 seniors living in Chiang Rai, northern Thailand (65 km south of Golden Triangle).

Thanks in advance!

 

77 nanometers?
77mm? is over 3 inches.
Can you please clarify or take a picture?

-Tom

 

I think he means 77nm - Newton Meters

It's the metric torque measurement.

1Nm = 0.7375 Ft-Lbs.

 

LOL. thanks.
So the wheel get jammed before he reaches the desired torque.
This is a tough one. The wheel shouldn't jam regardless how hard you torque the bolt.

 

Yes, it should not. We have tried everything but cannot understand why it get jammed.
Here a link with a XJ700 with same problem but they found out there was a spacer missing. http://xjbikes.com/Forums/viewtopic/t=34011.html

 

Make sure that the collar that rides between the wheel, and final drive is there. Easily lost when wheel is removed.

It keeps the wheel from binding in the final drive when torqued to spec.

Item #42 (top left corner)
http://www.yamahapartshouse.net/pages/O ... MOTORCYCLE)/DRIVE_SHAFT_(XJ650G_-_1980)

Ghost

 

Thank you MiGhost, Checking that one!
Sorry for late reply, some other problem in the project....
Thanks again!