This Haynes Yamaha XJ650 and XJ750 1980-1984 Repair Manual provides service, repair and maintenance information for XJ650 UK (1980-1984), XJ650 Maxim US (1980-1983), XJ650 US Midnight Maxim (1981), XJ650 R Seca US (1982), XJ750 UK (1981-1984), XJ750 US (1982-1983), XJ750 M Midnight Maxim US (1983), XJ750 R Seca US (1981-1983)
Note: This manual does not cover XJ650 Turbo Models

Table of Contents

Introduction
Model dimensions and weights, Ordering spare parts, Safety, Tools and working facilities, choosing and fitting accessories, routine maintenance.

Troubleshooting
Starter motor problems (Starter motor not rotating, Starter motor rotates but engine does not turn over, Starter motor and clutch function but engine will not turn over), Engine does not start when turned over (No fuel flow to carburetor, Fuel not reaching cylinder, Engine flooding, No spark at plug, Weak spark at plug, Compression low), Engine stalls after starting (General causes), Poor running at idle and low speed (Weak spark at plug or erratic firing, Fuel/air mixture incorrect, Compression low), Acceleration poor (General causes), Poor running or lack of power at high speeds (Weak spark at plug or erratic firing, Fuel/air mixture incorrect, Compression low), Knocking or pinking (General causes), Overheating (Firing incorrect, Fuel/air mixture incorrect, Lubrication inadequate, Miscellaneous causes), Clutch operating problems (Clutch slip, Clutch drag), Gear selection problems (Gear lever does not return, Gear selection difficult or impossible, Jumping out of gear, Overselection), Abnormal engine noise, (Knocking or pinking, Piston slap or rattling from cylinder, Valve noise or tapping from cylinder head, Other noises), Abnormal transmission noise, (Clutch noise, Transmission noise), Exhaust smokes excessively, (White/blue smoke (caused by oil burning), Black smoke (caused by over-rich mixture)), Oil pressure indicator lamp goes on, (Engine lubrication system failure, Electrical system failure), Poor handling or roadholding, (Directional instability, Steering bias to left or right, Handlebar vibrates or oscillates, Poor front fork performance, Front fork judder when braking, Poor rear suspension performance), Abnormal frame and suspension noise, (Front end noise, Rear suspension noise), Brake problems, (Brakes are spongy or ineffective, Brakes drag, Brake lever or pedal pulsates in operation, Brake noise, Brake induced fork judder), Electrical problems, (Battery dead or weak, Battery overcharged, Total electrical failure, Circuit failure, Bulbs blowing repeatedly).

Chapter 1 Engine, clutch and gearbox
General description, Operations with engine/gearbox in frame, Operations with engine/gearbox unit removed from, frame, Removing the engine/gearbox unit, Dismantling the engine/gearbox unit: general, Dismantling the engine/gearbox unit: removing the, cylinder head cover and camshafts, Dismantling the engine/gearbox unit: removing the, cylinder head, Dismantling the engine/gearbox unit: removing the, cylinder block and pistons,, Dismantling the engine/gearbox unit: removing the ignition, pick-up assembly and crankshaft end covers, Dismantling the engine/gearbox unit: removing the, alternator, Dismantling the engine/gearbox unit: removing the clutch, assembly, Dismantling the engine/gearbox unit: removing the oil, pump and drive, Dismantling the engine/gearboxunit: removing the starter, motor and gearchange mechanism, Dismantling the engine/gearbox unit: removing the middle, gear assembly, Dismantling the engine/gearbox unit: separating the, crankcase halves, Dismantling the engine/gearbox unit: removing the, crankcase components, Examination and renovation: general;, Examination and renovation: main bearing and big-end, bearing selection, Examination and renovation: crankshaft assembly, Examination and renewal: gaskets, oil seals and 0-rings, Examination and renovation: connecting rods, Examination and renovation: cylinder bores, Examination and renovation: pistons and piston rings, Examination and renovation: cylinder head and valves, Examination and renovation: camshafts, camshaft bearings and cam followers, Examination and renovation: camshaft chain, drive, sprockets and tensioner blades, Examination and renovation: starter shaft, chain and, sprockets, Examination and renovation: starter clutch, Examination and renovation: clutch assembly, Examination and renovation: gearbox components, Examination and renovation: gear selector mechanism, Examination and renovation: middle gear assembly, Engine reassembly: general, Engine reassembly: refitting the upper crankcase, components, Engine reassembly: refitting the lower crankcase, components, Engine reassembly: joining the crankcase halves, Engine reassembly: refitting the oil pump, pump drive, components and sump, Engine reassembly: installing the middle gear, components, Engine reassembly: middle gear backlash - checking and, adjustment, Engine reassembly: checking and shimming the middle, driving shaft, Engine reassembly: refitting the clutch, Engine reassembly: refitting the gear selector mechanism, and left-hand cover, Engine reassembly: installing the alternator, Engine reassembly: refitting the starter motor, Engine reassembly: refitting the ignition pick-up and, neutral switch lead, Engine reassembly: refitting the pistons and cylinder, block, Engine reassembly: refitting the cylinder head, Engine reassembly: refitting the camshafts and setting, the valve timing, Engine reassembly: refitting the cylinder head cover, Engine reassembly: refitting the engine/gearbox unit, Starting and running the rebuilt engine, Taking the rebuilt machine on the road.

Chapter 2 Fuel system and lubrication
General description, Petrol tank: removal and replacement, Fuel tap: removal, overhaul and reassembly, Fuel feed pipe: examination, Carburetor adjustment and exhaust emissions:, general note, Carburetors: removal, Carburetors: dismantling, overhaul and reassembly, Carburetors: checking the fuel level, Yamaha YICS system: general description - All XJ750, XJ650J and XJ650 - 11N (UK) models, Carburetors: synchronization - YICS models, Carburetors: synchronization — non YICS models, Carburetor settings, Exhaust system, Air cleaner: location and maintenance, Crankcase ventilation system: description and, maintenance, Engine lubrication, Oil pump: dismantling, examination and reassembly, Oil filter: function and renewal, Oil cooler: general description - UK models.

Chapter 3 Ignition system
General description, Testing the ignition system: general information, Ignition system faults: tracing the defective area, Ignition coils: spark gap testing, Ignition coils: resistance tests, Pick-up coils: resistance test, TCI unit: testing, Ignition timing: checking and resetting, Spark plugs: checking and resetting the gaps.

Chapter 4 Frame and forks
General description, Front forks: types and applications, Front fork legs: removal and replacement - centre axle, types', Front fork legs: removal and replacement - leading axle, type, Front fork legs: removal and replacement - leading axle, type with adjustable air pressure and damping, Front fork legs: removal and replacement - leading axle, type with adjustable air pressure and anti-dive, Steering head assembly: removal and replacement —, XJ650(UK) and XJ650 RJ, Steering head assembly: removal and replacement -, XJ650 G, H, LH and J models, Steering head assembly: removal and replacement -, XJ750(UK), XJ750RH and RJ, Steering head assembly: removal and replacement -, XJ750J, Front forks: dismantling and reassembly — general, Front forks: dismantling and reassembly - XJ65CHUK), and XJ650 G, H, LH and RJ, Front forks: dismantling and reassembly - XJ650 J, Front forks: dismantling and reassembly - XJ750 J, Front forks: dismantling and reassembly -, XJ750IUK), XJ750RH and RJ, Front forks: examination and renovation, Steering head bearings: examination and renovation, Frame: examination and renovation, Swinging arm bearings: checking and adjustment, Swinging arm: removal, renovation and replacement, Final driveshaft: removal, renovation and installation, Final drive bevel gears: fault diagnosis, Rear suspension units: examination — XJ650 models Rear suspension units: examination — XJ750 models, Suspension adjustment, Front fork adjustment procedures, Centre stand: examination, Prop stand: examination, Footrests: examination and renovation - all models, except XJ750 J, Footrests: examination, renovation and adjustment -, XJ750J, Rear brake pedal: examination and renovation - all, models except XJ750 J, Rear brake pedal: examination and renovation -, XJ750J, Gear change pedal: examination and renovation -, XJ650G, H, LH, J and XJ750J, Gear change linkage: examination and renovation - all, UK models and all US Seca models, Gear change linkage: examination and adjustment -, XJ750J, Handlebar adjustment: XJ750 J, Dual seat: removal and replacement, Helmet lock: general description, Steering lock: location and renewal, Security chain: location and renewal, Instrument panel: general, Speedometer drive gearbox and cable: examination, Tachometer drive gearbox and cable: examination -mechanical tachometer models.

Chapter 5 Wheels, brakes and tires
General description, Front wheel: examination and renovation, Front wheel: removal and replacement, Front disc brake: checking and renewing the pads - XJ650(UK) and XJ750 RJ, Front disc brake: checking and renewing the pads - XJ650 G, H, LH and J, Front disc brake: checking and renewing the pads - XJ750(UK), XJ750 RH and RJ, Front disc brake: checking and renewing the pads - XJ750 J, Front disc brake: overhaul - general notes, Front disc brake: removing, renovating and replacing the caliper units - XJ650IUK) and XJ650 RJ, Front disc brake: removing, renovating and replacing the caliper unit - XJ650 G, H, LH and J, Front disc brake: removing, renovating and replacing the caliper units - XJ750(UK), XJ750 RH and RJ, Front disc brake: removing, renovating and replacing the caliper units - XJ750 J, Handlebar - mounted master cylinder: overhaul - all models except XJ75CHUK), XJ750 RH and RJ, Frame-mounted master cylinder: overhaul - XJ750(UK), XJ750 RH and RJ, Anti-dive actuating valve housing: overhaul -XJ750(UK), XJ750 RH and RJ, Hydraulic brake hoses and pipes: examination, Bleeding the hydraulic system — All models except XJ750 (UK), XJ750 RH and RJ, Bleeding the hydraulic system: XJ750IUK), XJ750 RH and RJ, Removing and replacing the brake disc, Front wheel bearings: examination and renovation, Rear wheel: examination, removal and replacement, Rear wheel bearings: examination and replacement, Rear drum brake: examination and renovation, Adjusting the rear drum brake, Tires: removal and refitting - tubeless tires, Puncture repair and tire removal - tubeless tires, Tire valves: description and renewal - tubeless tires, Tire valves: description and renewal - tubeless tires, Tires: removal, repair and refitting - tube tires, Valve cores and caps: tube tires, Wheel balancing.

Chapter 6 Electrical system
This book features complete wiring diagrams.

General description, Electrical system testing: general information, Charging system: output check, Alternator: rotor and stator resistance tests, Voltage regulator/rectifier unit: testing, Battery: examination and maintenance, Battery: charging procedure, Fuses: location, function and renewal, Starter motor: removal, examination and testing, Starter solenoid switch: function, location and testing, Headlamp: bulb renewal and beam alignment - XJ650(UK), and XJ650 RJ Seca, Headlamp: unit renewal and beam alignment - XJ650 G, H, LH and J, Headlamp: bulb renewal and beam alignment - XJ750(UK), and XJ750 RH, RJ and J, Auxiliary lamp: bulb renewal and beam alignment -, XJ750IUK), XJ750 RH and RJ, Stop/tail lamp: bulb renewal - XJ650(UK) and, XJ650RJ, Stop/tail lamp: bulb renewal - XJ650 G, H, LH and J, Stop/tail lamp: bulb renewal - XJ750(UK), XJ750 RH, RJ, and J, License plate lamp: bulb renewal - XJ750(UK) and, XJ750RH, RJ, J, XJ650G, H, LH and J, Flashing indicator lamps: bulb renewal, Parking lamp: bulb renewal - UK models ), Circuit testing: general procedures, Flasher relay: location and testing :, Self-canceling circuit: description and testing, Handlebar switches: maintenance and testing ', Main switch: maintenance, testing and renewal, Stop lamp switches: location, testing and adjustment, Neutral switch: location, function and testing, Clutch switch: location, function and testing, Side stand switch: location, function and testing - XJ650 J and RJ, XJ750IUK), XJ750 RH, J and RJ, Side stand relay: location, function and testing -, XJ750(UK), XJ650 J, RJ, XJ750 RH, J and RJ, Engine oil level switch: general information, Front brake fluid level switch: general description -, XJ750IUK), XJ750RH, RJ, and J, Starter interlock system: general description — XJ650 J, RJ, XJ750(UK), XJ750 RH, J, and RJ, Starting circuit cut-off relay: location and testing, - XJ650J, Starting circuit cut-off relay: location and testing -, XJ750IUK), XJ750RH, J and RJ, Side stand relay: location and testing - XJ650 J, RJ, and XJ750(UK), Side stand relay: location and testing - XJ750 RH, RJ, and J-, Diode block: description, location and testing, Starter interlock system: general description -, XJ650IUK), XJ650G, H, and LH, Starter interlock system: fault diagnosis -, XJ650(UK), XJ650G, H, and LH :, Computer monitor system: general description -, XJ750(UK), XJ750 RH, RJ, and J, Computer monitor system: fault diagnosis, Computer monitor system: removing and refitting the, microprocessor and LCD panel, Battery condition sensor: general description and, maintenance - XJ750(UK), XJ750 RH, RJ and J, Fuel level sender: operation and testing -, XJ750(UK), XJ750 RH, RJ and J, Warning lamps: bulb renewal - XJ750(UK), XJ750 J, RJ, and RH, Instrument panel: dismantling and bulb renewal - All, models except XJ750(UK), XJ750 RH and RJ, Horn: location and examination — All models except, XJ750 RH and RJ, Horn: location - XJ750 RH and RJ.

Chapter 7 The 1983 US models
Introduction, Engine/gearbox unit: modifications, Carburetor: modifications, Air filter: general, Front forks: general - XJ750 K and MK, Steering damper: general - XJ750 RK, Fairing and luggage: general - XJ750 RK, Brake hoses: general - XJ750 models, Instruments, lighting and electrical system: general XJ750 K and MK.