cylinder and head dowel locations and grommet orings

I am working on a 1982 Yamaha XJ650 YICS engine. I understand the right hand side two outermost cylinder / cylinder head studs also carry pressure oil from the case up to the cylinder head. In the Haynes manual it shows a pair of dowels and o rings between the cylinder head and the cylinders. But it shows nothing between the cylinder and the case. Other than the tissue thin base gasket. I am certain there must be some sort of seal to keep the pressure oil in the passage and not all over the roads we ride on.

While I am at it does anyone have a real factory manual that I can download? The Haynes is only barely better than the Clymers. But I would look into the Clymers manual to see if they have better photos etc... If anyone has one...

Anyone out there versed on Yics XJ650 engine overhaul?

BTW.... If any of you are considering buying cheap ring-sets from a chap in Japan for 40 dollars.... I just got my rings in for the 1982 Yamaha XJ650.... And they are wrong.... BBBssssttt Ya get what ya pay for.... He sent me a top ring and a second ring the same thickness And I need a thicker second ring. If anyone ever used these rings from this Japanese chap... Your motor will smoke and burn oil. I had to reuse my old second groove rings.

 

The FSM shows and reads that there are O Rings on the right side dowels as well.

There are places to download the FSM online. I have it but not sure how I can send to you, its about 23MB.

 

maxim or seca?
here is a link to seca maxim fsm $8.95 download
http://www.tradebit.com/filesharing.php/search/0/1982+yamaha+xj650+maxim

check out this thread from jayrodoh
http://www.xjbikes.com/forums/threads/head-installation-sanity-check.69186/

 

Those are not o_rings. It's a special gasket.
Chacal has them

 

I would think a full gasket set from Athena would include whatever is needed. If one or the other area needs sealing then the base does not? or the head does not?
I am still perplexed.

 

I have a yahoo mail account if it will accept a large attachment....
mikestp@yahoo.com
Would definitely appreciate it. The Haynes manual does not show it.....

 

The base seal on the head bolt oil passages comes from two normal (but special size) o-rings. The seal at the head/cylinder junction comes from two special "O-rings". And the seal at the top of the head comes from the two special-sized, copper-plated steel crush washers. The set Chacal sells has all of them, as does the Athena gasket set (if you get the full engine sets. The head only sets will not have the o-rings for the base). There are dowels/collars in all four locations. I suspect that you bought/ were sent the wrong Athena kit, or that you were shorted parts.

 

Just be aware that the Athena kits do not contain the copper crush washers, and the o-rings for the jugs-to-crankcase are not really the proper size.......and the "o-rings" at the head-to-jugs interface are really big squishy rubber gaskets, rather than just standard o-rings.

And make sure you realize that the upper and lower dowel pins are different.

Every word above weighs a ton.

 

They don't even contain the regular steel washers anymore (IIRC they used to).

 

That statement is correct.

 

Email sent.

Chacal can hook you up, not sure what gasket set you bought but you'll need these in addition to a base gasket:

 

Just for clarification: the top-end gasket kits that we offer do include the large base O-rings (the red ones shown above), the valve stem rubber oil seals, and the HCP5826 head-to-jugs oil passage squishy rubber gaskets.

The correct size jugs-to-crankcase o-rings (HCP4696 above) are not included in the top-end GASKET kit, but are included in our TOP END O-RINGS and CRUSH WASHERS KIT :


XJ650 yics engines:

NOTE: yics engines were originally used in all 1982-84 XJ650 Maxim engines, 1982-84 XJ650 Euro (14R) models, and 1982 XJ650RJC Seca (Canadian models with YICS engine).


HCP5470 Aftermarket TOP-END GASKET KIT, for all 1982-84 XJ650 Maxim engines, 1982-84 XJ650 Euro (14R) models, and 1982 XJ650RJC Seca (Canadian models with YICS engine).
$

The HCP5470 set includes:
- valve cover gasket
- valvecover inner (4) and outer (8) pressure washers
- cylinder head gasket
- camshaft chain tunnel gasket
- cam chain tensioner gasket
- intake manifold gaskets (4)
- exhaust port ring gaskets (4)
- cylinder jugs gasket
- cylinder jugs large o-rings (4)
- valve stem seals (8)
- cylinder head-to-jugs rubber donut oil seals, used on the #4 cylinder outer studs (2)



We recommend the following accessory kits to compliment the above gasket kit:

HCP21502 Aftermarket TOP END O-RINGS and CRUSH WASHERS KIT, contains all of these additional items which are needed to do a top-end service, and are not included in the top-end gasket kit. Highly recommended. Contains the following items:

- 1 x cam chain rear guide adjuster O-RING.
- 4 x yics passage jugs-to-head O-RINGS. NOTE: XJ650 Turbo engines use the yics passage o-rings that come in the gasket kit.
- 2 x jugs-to-crankcase O-RINGS used on the #4 cylinder outer studs
- 1 x automatic camshaft chain tensioner copper CRUSH WASHER.
- 2 x cylinder head stud copper CRUSH WASHERS, used under the #4 outer studs front/rear crown nuts
- 1 x oil filter bypass valve and cover mounting bolt O-RING.
- 1 x oil filter cover-to-block O-RING.
- 1 x oil pan drain bolt CRUSH WASHER.
- 5 x cylinder stud SHEATHING.
- 2 x cylinder head YICS passage bolt copper CRUSH WASHERS.
- 1 x cylinder casting port screw CRUSH WASHER. (used on 1983 XJ550 models, 1982-3 XJ650 Maxim, 1983 XJ650 Turbo, all XJ700 air-cooled, 1982-83 XJ750, and XJ900 models).

Fits all 1982-83 XJ650 models (yics engines), all XJ700 all air-cooled, all XJ750 all air-cooled, and all XJ900 engines.
$


HCP22323 Aftermarket OIL COOLER O-RINGS KIT, contains all of these additional items which are needed to do an oil cooler removal and replacement, and are not included in the gasket kit or in the standard top-end or complete o-rings and crush-washers kit. Highly recommended. Contains all of the following items:

- 2 x oil cooler hose-to-adapter housing O-RINGS.
- 2 x oil cooler hose-to-oil radiator O-RINGS.
- 1 x oil filter cover-to-block O-RING.

Fits all XJ550, XJ650, and XJ750 (except XJ750RL) models with the factory-installed oil cooler system.
$



HCP22339 Aftermarket TOP END HARDWARE KIT, contains all of the special hardware pieces which are needed to do a top-end service, and are not included in the top-end gasket kit. Although you may not think that you need these items, you may quickly discover that you do, since they tend to get seized and rusty and/or damaged (bent, out-of-round) during the engine dis-assembly process. Contains the following items:

- 5 x locating DOWEL PINS used at:
* the cylinder head-to-jugs interface at the #4 outer studs front/rear (2) (these positions use the “donut” oil seals)
* the cylinder head-to-jugs interface in-between the #3/4 front studs (1)
* the cylinder head-to-jugs interface at the #1 rear outer stud (1)
* the jugs-to-crankcase DOWEL PIN at the top outer #1 stud rear position
- 2 x jugs-to-crankcase top DOWEL PINS at the #4 outer studs front/rear (these positions use the o-rings)
- 12 x cam bearing caps-to-cylinder head DOWEL PINS

Fits all XJ650, all XJ700 air-cooled, and all XJ750 air-cooled engines.
$

 

Top End, Case split or both? Yes, this forum is versed. Member/vendor/guru Chacal, who posted above, has everything you'll need to do either or. Welcome aboard.

Gary H.

 

Top End, Case Split or both? Yes, this forum is versed. Member Chacal, who posted above, has everything you'll need to do it. Welcome aboard.

Gary H.

 

I am just doing a top end overhaul. Rings, gaskets, cyl head, in the bike.... engine NOT removed.

 

Well that is now clear. Thanks very much. the larger dowels are in the case, the smaller dowels and the enongated dougnuts are in the cyinder head. What was throwing me off is the larger dowels will actually fit in the cylider head.....

Thanks Mike...

 

We've got you covered.

Gary H.