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Intake Boots (Between Carbs and Head) - Identifying Correct P/Ns?

Discussion in 'XJ Technical Chat' started by larsony99, Feb 8, 2020.

  1. larsony99

    larsony99 New Member

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    Hello all. My wife has an '82 XJ650 that we're trying to get running again, and we need to replace the intake boots that go between the carbs and the head. She previously purchased parts, and we got them in. We were all set to install them, but we ran into a problem. We ordered 2 different part numbers (as that's what's on her bike), but we actually received 3 different parts.

    She decided not to send them back (I have no idea why, since they were expensive), but I want to buy her the right parts. The problem is when I go on Bike Bandit or Partszilla to get parts, the parts diagram is not correct for what's actually on her bike.

    Here's the parts diagram:
    Items 1 & 2.
    Photo below
    And here's the parts listing:
    5G2-13586-02-00
    5G2-13596-01-00

    However, the bolt holes are in a different orientation on her bike:
    Photo below

    I really want to make sure I order the right parts as they're very expensive. In addition, it clearly shows 2 different part numbers, but they look the same in the diagram.

    Has anyone ran into this before? Can anyone help me get the right parts?
     
    Last edited: Feb 8, 2020
  2. larsony99

    larsony99 New Member

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    Parts Diagram
    2020-02-08_18-48-36.png
     
  3. larsony99

    larsony99 New Member

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    Here's the photo of the boots we have.
     

    Attached Files:

  4. kosel

    kosel Active Member Premium Member

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    Which 650 do you have? YICS and non-YICS engines have some differences.
     
  5. XJ550H

    XJ550H Well-Known Member Premium Member

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    is the bike a Seca or Maxim?
    82 Seca has non YICS motor
    Maxim Has YICS motor

    start by IDing the bike and Motor

    TECH TOPIC: Model ID and VIN's


    82 650 look at the vin on motor you want to see 5N8 or 5V2 in short vin.
    MODEL NAME: XJ650J
    STREET NAME: 1982 XJ650 Maxim
    MODEL ID CODE: 5N8

    MODEL NAME: XJ650RJ
    STREET NAME: 1982 XJ650 Seca
    MODEL ID CODE: 5V2


    run frame vin AND motor vin if diffrent through this link

    http://www.dissingermoto.com



    the seca nonyics motor has

    JOINT, CARBURETOR 2 (5G2-13596-
    5G2-13596-01-00


    JOINT, CARBURETOR 1 (4H7-13586-
    4H7-13586-02-00


    the valve cover should say YICS on top for the boots you ordered
    yicsvc.PNG


    non yics motor valve cover also has diffrent bolt pattern see below
    secavc.PNG


     
    jayrodoh likes this.
  6. jayrodoh

    jayrodoh YimYam Premium Member

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    You have the wrong ones. The motor in your pic is a YICS motor and the ones you ordered are for the non YICS. When you look up parts on partzilla make sure you are looking at model 82 XJ650J and not 82 XJ650RJ
     
  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    and you only need to buy 2 as 1 part number goes on both style motors.

    except you say you 3 different styles
     
  8. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    XJ650, XJ700, and XJ750 engines:

    NOTE: the non-YICS (1980-81 XJ650 Maxim/Midnight Maxim and 1982 XJ650RJ Seca) left side (cylinders #1 and #2) manifolds differ from the YICS (1982-84) manifolds in the orientation of their mounting:

    * non-YICS engines have the intake manifold mounting bolt holes in the cylinder head aligned in this manner:

    <#1 \ \ \ \ #4>

    * YICS engines have the intake manifold mounting bolt holes in the cylinder head aligned in this manner:

    <#1 / / \ \ #4>

    This is why the left side (cylinders #1 and #2) intakes differ between the YICS and non-YICS engines, and why they are the same for the right side (cylinders #3 and #4) on all XJ650 non-Turbo engines!


    1980-81 XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca with non-yics engines:

    * non-YICS engines have the intake manifold mounting bolt holes in the cylinder head aligned in this manner:

    <#1 \ \ \ \ #4>



    The right side (cylinder #3 and #4) manifolds are the same for all models/years of XJ650 non-turbo and all 1981-83 XJ750 air-cooled engines. The left side is unique and different between the YICS and non-YICS engines. Note that XJ700 air-cooled and 1984 XJ750RL Seca engines use a different type/style intake manifold(s) that are completely different from the other models, and will not interchange.

    Note that we always have the correct manifolds in stock!
     
  9. larsony99

    larsony99 New Member

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    Thanks everyone for the replies. I'm trying to be sneaky to try and get them for Valentine's Day if I can, and I'm out of state. I have to look through my photos because I swear I took pictures of the engine.

    I'll report back later.
     
  10. Bushy

    Bushy Active Member

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  11. Timbox

    Timbox Well-Known Member

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    Speaking of those pics, we would like to see how bad the old ones were. Not saying you want to keep them but there are ways to make them come back to live and then to seal the cracks that are in them. Sure they would not look as nice as OEM but they would work and get you back on the road. Just a thought.
     
  12. XJ550H

    XJ550H Well-Known Member Premium Member

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  13. larsony99

    larsony99 New Member

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    Well, we ordered 2x each of two different part numbers. The bags showed 2x of 2 part numbers, but we physically received 3 different parts (1x, 1x, and 2x). So, somebody at the factory screwed up.

    I tried to get my wife to send them back and she wouldn't (don't ask why.... I don't know).
     
  14. larsony99

    larsony99 New Member

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    Here's the one of the boots. Looks like they were "repaired" before.

    Her bike hasn't ran in a few years. When she bought it, it stopped running if you didn't warm it up every day. I decided she needed to replace everything involved with pulling vacuum, because it appears to not be pulling fuel when you try try start it.
     

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  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    that could be a bad battery, or the fuel evaporating from carbs when bike sits.
    if battery voltage drops below 10 volts when starter is cranking bike will not start.

    fuel evaporates from carbs when bike sits for several days or less depending on temps outside and if stored in a garage that gets hot. 5 or 10 seconds on prime refills the bowls.
    if you look at the back side of carbs there are 2 holes in the throat that go directly into bowls air vents
     
  16. larsony99

    larsony99 New Member

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    Thanks, I'm sure I'll be logging back on when we get it together and try to start it. How is it primed? The new boots should have been delivered by now. I've not received a sitrep on whether they're right lol. She works full time and is in her last semester of school (also full time).
     
  17. XJ550H

    XJ550H Well-Known Member Premium Member

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    the petcock has 3 positions run ,res(erve) and prime turn to prime count to 10 turn to run.
     
  18. larsony99

    larsony99 New Member

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    Well, I finally got her to open the box and check the boots. They are the correct parts. Thank you everyone for the help!
    Now, I just have to get her to start working on it LOL. Not likely as we're getting our house ready to rent. :rolleyes:

    Oh well, for another thread.
     
  19. larsony99

    larsony99 New Member

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    This is actually super helpful as the previous owner replaced the petcock with an aftermarket one. It has no prime position... Wow. Sometimes it's a stupid little detail.
     
  20. larsony99

    larsony99 New Member

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    Last edited: May 18, 2020

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