J. Crankcase Disassembly
1. Remove the upper crankcase bolts, starting the highest numbered bolt. Turn over the engine and remove the lower crankcase bolts,
CRANKCASE TORQUE SEQUENCE
UPPER CASE
LOWERCASE
The following is a guide to determing if a used TCI is appropriate for a given machine:
This series assumes you took the carbs apart, and are trying to figure out how to put them back together again. If you haven’t taken them apart yet, it’s a good idea to skim through this first anyway. Address any questions to: xj-owners@micapeak.com, and we’ll try to talk you through it.
Pictures and text by Dwayne Verhey
F. Cylinder
1. Inspect the cylinder walls for scratches. If vertical scratches are evident, the cylinder wall should be rebored or the cylinder should be replaced.
2. Measure cylinder wall wear as shown. If wear is excessive, compression pressure will decrease. Rebore the cylinder wall and replace the piston and piston rings. Cylinder wear should be measured at three depths with a cylinder bore gauge. (See illustration.)
13. Remove the front cylinder holding nut and remove the cylinder assembly. It may be necessary to tap the cylinder lightly to loosen it from the base gasket.
14. Remove the rear cam chain guide by loosening the holding bolt.
1. Holding bolt 2. Rear cam chain guide
CHAPTER 5. CHASSIS
FRONT WHEEL
A. Removal
1. Place the motorcycle on the center stand.
2. Remove the cotter pin and wheel axle
3. Remove the speedometer cable holder securing bolt.
CHASSIS
A. Fuel Petcock
If the fuel petcock is leaking or excessively contaminated, it should be removed from the fuel tank and inspected.
1. Remove the fuel tank and position it so that fuel will not spill when the petcock is removed.
XJ650RJ CIRCUIT DIAGRAM
2. Lower crankcase
a. Install the shift cam and secure it with the guide pin. Install the stopper plate and bolt and tighten securely.
b. Install the neutral switch.
c. Install the transmission drive axle assembly into the crankcase.
ENGINE OVERHAUL
A. Cylinder Head and Cylinder
1. Remove the cylinder head cover.
2. Remove the left crankcase cover (pickup coil cover).
3. Remove the cam chain tensioner.
