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SECTION P:
THE TOOLBOX, LOWER DRAWERS:
Carb Cleaning Tools:
p1) Aftermarket CARB PASSAGES CLEANING WIRES KITS: these sets of small wire tip cleaners come in a handy aluminum flip-open case, and are essential for probing and cleaning some of the smallest internal passages within the carb bodies to push out and free up solidified fuel "gunk" and other obstructions before blasting the passages with cleaner and compressed air. The #6 and #7 size wires are the only sizes small enough to fit into the tiny jet passages and emulsion tube holes and clean them properly (without the risk of "re-sizing" the hole by mistake). NOTE: even the smallest #6 wire is too large to clean the starter jet down in the bowl! For that task, you'll need to order the correct bowl starter jet drill bits listed further below.
HCP950 Carb Passages MINI CLEANING WIRES TOOL SET, contains 13 wires (sizes #6 - 26) and a small flat file.
$ 9.95
HCP951 Carb Passages MINI-PLUS CLEANING WIRES TOOL SET. Same as the MINI set above, but contains an extra 3 (each) of the #6, #7, and #8 size wires (the smallest ones) so even if you ruin one, you'll have lots of spares (being so thin, they're very easy to break!). The miniature file---which you don't really need---is not included in this set.
$ 11.95
HCP953 Carb Passages MAN-SIZE CLEANING WIRES TOOL SET contains 22 small wire tip cleaners, sizes #6-45, in a handy aluminum flip-open case.
$ 12.95
ft2) Aftermarket twisted-stem WIRE-BRISTLE CLEANING BRUSHES. The greatest tool ever invented for cleaning bored and threaded holes, such as in carb bodies, float bowls, even master cylinder piston bores. Available in either 18-8 stainless steel or brass, these brushes not only help make the job of cleaning parts so much easier, but also insure that threaded passages are clean, clean, clean and less likely to strip or deform when fasteners are inserted once again. All brushes have a "finger-loop" in the end to make twisting action easier. Stainless brushes will last longer and can clean more aggressively, so be gentle when using them on aluminum carb bodies and bowls. Brass brushes are gentle on soft metals like carb bodies, but require more effort to produce a cleaner surface and wear out more quickly.
Please see the complete assortment of sizes for these products listed in the "General Tools - Cleaning and Polishing Tools and Supplies" section in the previous post.
cps2) Aftermarket high-quality WET-OR-DRY FINISHING SHEETS. Since these don't contain "sand", we really can't call them "sandpaper", but you get the idea. A large assortment of ultra-fine finishing paper is just the trick to polish the vacuum pistons and piston bores in your carbs, or master cylinder and brake caliper bores, ridding them of any surface oxidation and minor imperfections that will create interference or friction and prevent the pistons from moving freely---causing all sorts of high-idle (and other problems) in your carbs, or dragging brakes in your calipers. Our recommendation is to start with the 400- or 600-grit paper and move up 200 grit at a time until you get the bores micro-polished to an incredible smooth finish. One 9.5" x 11" sheet of each size will be enough to do four carbs or one pair of calipers; use two sheets of the 5-1/2" x 11" super-fine grit paper.
Of course, this premium finishing paper is just the thing you'll need for prepping any painted surface for painting, too.
Please see the complete assortment of sizes for these products listed in the "General Tools - Cleaning and Polishing Tools and Supplies" section in the previous post.
z7) Aftermarket wire BOWL STARTER JET CLEAN-OUT TOOLS. As you will quickly discover if you ever try to clean or rebuild your carbs, the tiny, non-removable starter jet that is stuck wa-a-a-y down at the bottom of a drilled passage in the carb bowl is next to impossible to clean. For one, did we mention that the jet opening is TINY? And did I also mention that it's stuck way down at the bottom of a small passageway, and basically unreachable? AND THEREFORE, NO ONE EVER REALLY EVEN ATTEMPTS TO CLEAN IT OUT? And that a clogged starter jet not only means trouble starting and idling, but that starter circuit is actually also involved in idle and off-idle performance? Well, how do you actually clean it? Even the tiniest cleaning rod in our carb passage cleaning wire sets (above) aren't small enough to fit through this starter jet (it is THE smallest jet-passage in the entire carb)...
Well, here's how you clean it: with these jet clean-out tools. Just big enough to get through the jet, but not big enough to ENLARGE the jet (that's a huge no-no), these high-speed steel STARTER JET DRILL BIT or the STARTER JET WIRE PROBE TOOL. The drill bits can be gently rotated (but never "pushed", as it will break), while the stiff pointed-tip wire probe tool can be twirled to dig through the toughest of crud. This is the only way to properly clean these starter jets.
NOTE: these are TINY drill bits, and will not chuck into a standard drill chuck. You have to use a mini pin-vise attachment or do it carefully by hand.
COMPARISON: these drill bits are a mere 1-1/2" long, and as such, will disappear below the top "plane" of the bowl as it goes down into the jet. You will have to use a pair of very slim needle-nose pliers to grip the tip of this drill bit and rotate it! The probe tools have a long piece of semi-rigid steel wire attached at the end of a hand-held "pen" stick.
The drill bits are harder to manipulate, but do a better job since they have a "cutting edge" on the tip.
The probe tools are easier to manipulate, but don't do quite as good a job since they do not have any type of "cutting edge" on the tip....but are still sharp enough to "pick" through most types of sludge and build-up in the jet.
NOTE: The 1980-81 XJ650 carb bowls should have removable bowl starter jets, which will make your life a lot easier!
http://xjbikes.com/forums/index.php?threads/43931
HCP2296 Aftermarket BOWL STARTER JET DRILL BIT, for Hitachi carb bowls used on all XJ650 (except Turbo) models and all 1981-83 XJ750 models.
$ 13.95
HCP2299 Aftermarket BOWL STARTER JET DRILL BIT, for Hitachi carb bowls used on all XJ750E-II and XJ750RL models.
$ 13.95
HCP12929 Aftermarket BOWL STARTER JET WIRE PROBE TOOL, for Hitachi carb bowls used on all XJ650 (except Turbo) models, all 1981-83 XJ750 models, and XJ750E-II and XJ750RL models.
$ 10.95
HCP2293 Aftermarket BOWL STARTER JET DRILL BIT, for Mikuni carb bowls used on all XJ550 models, XJ650 Turbo models, all XJ700-X and XJ750-X models, and XJ900 N/FN, and F models, and Hitachi carb bowls used on XJ700 air-cooled engines.
$ 13.95
HCP12927 Aftermarket BOWL STARTER JET WIRE PROBE TOOL, for Mikuni carb bowls used on all XJ550 models, XJ650 Turbo models, all XJ700-X and XJ750-X models, and XJ900 N/FN, and F models, and Hitachi carb bowls used on XJ700 air-cooled engines.
$ 10.95
P.S. how do you know when your starter jet is really, truly, zestfully clean? One of two ways:
a) shine a strong penlight or mini flashlight into the bottom of the bowl, where this jet passage "intake" is located. Look through the top of the bowl down into the jet passage "outflow" passage (this is the passage that the brass suction tube in the bottom of the carb body actually fits down into). Focus your eye carefully on the jet opening and make sure it's clean. P.S. it helps to do all this while in a darkened area.........see the picture "starter-jet.jpg" on page 2 of this forum thread topic for a great image of what you want to see!:
http://xjbikes.com/forums/index.php?threads/4050
b) put the spray tip (you may have to gently shape the end of it to a fine point, see the video below) of a can of carb or brake cleaner into the intake opening of the starter jet and let rip a spray. A STEADY, FINE, POWERFUL STREAM OF FLUID WILL COME OUT OF THE OUTFLOW PASSAGE ON THE TOP OF THE CARB BOWL IF THE JET IS PERFECTLY CLEAN AND OPEN. I mean this stream will absolutely spit out a good 5-10 feet. If the stream isn't powerful and laser-like precise coming out of the jet, then the jet isn't zestfully clean.....
By the way, when using the spray-stream method of checking the jet, don't even THINK of putting your eye or face anywhere even NEAR the jet outflow path, unless you like a painful and potentially serious trip to the emergency room.
c9) Hitachi & Mikuni carbs THREAD CHASER AND CLEAN-UP TAPS. The soft aluminum bodies of the carbs can take a severe beating over the years, especially as it concerns their threaded holes. Steel is harder than aluminum, so you know what's going to distort, deform, or strip first...the threaded bore holes. The following professional quality tool-steel metric cutting taps will allow you to either "clean-up" or re-thread distorted or stripped threads in all metals, soft (aluminum) to hard (steel). THE TINY THREADS OF THE IDLE MIXTURE SCREW PORT IS ESPECIALLY PRONE TO DAMAGE AND SHOULD BE "CLEANED" UP WITH A PASS OF A THREADING TAP.
HCP28194 Aftermarket carb body THREAD CHASER BASIC TAPS SET. This basic set of 6 taps contains all of the different sizes for the most commonly needed threaded holes on all Hitachi and Mikuni carb bodies. Almost all threaded will exhibit some type of thread wear (distortion) or minor injury that should be repaired, especially to the smaller, more “fragile” threads on the mixture screw bores, the fuel and are jets threads, the bowl, hat, and bracket mounting holes, etc. Running thread taps thru all of these threaded holes in the carb bodies will not only make the re-assembly process easier, smoother, and more secure, but there is a certain satisfaction and surety that comes with having like-new threads that can only be described as “machinist porn” (those of you that know, will know what I mean!). Correct size taps will do the upper and lower rack bracket holes, the float bowl attachment holes, the float bowl drain screw holes, the carb hat attachment holes, synch screws and idle speed bolt holes, the Mikuni float valve seat bracket hole, Mikuni main jet needle retainer plate holes (inside the vacuum piston), all air jet and fuel jet holes, enrichment plunger lifter bracket holes, and throttle shaft butterfly valve mounting holes. Comes with a can of cutting fluid and a t-handle tap holder tool. Note that unlike the complete taps set below (HCP28121), the taps for the Hitachi float valve seat and the choke plunger seat bores (on all Hitachi and Mikuni models) are not included in this set (those larger taps are what add significantly to the cost of the complete taps set). NOTE: due to the reality that you may use these tools only once, it is suggested that you use the tool rental option for this tap set. However, under the rental option, if you use the taps for actual thread tapping (cutting brand new threads in a newly drilled hole), then the return option is not allowed!
$ 99.95
HCP28121 Aftermarket carb body THREAD CHASER COMPLETE TAPS SET. This complete set of 9 taps contains all of the different sizes of threads found on all Hitachi and Mikuni carb bodies. Almost all threaded will exhibit some type of thread wear (distortion) or minor injury that should be repaired, especially to the smaller, more “fragile” threads on the mixture screw bores, the fuel and are jets threads, etc. Running thread taps thru all of the threaded holes in the carb bodies will not only make the re-assembly process easier, smoother, and more secure, but there is a certain satisfaction and surety that comes with having like-new threads that can only be described as “machinist porn” (those of you that know, will know what I mean!). Correct size taps will do the upper and lower rack bracket holes, the float bowl attachment holes, the float bowl drain screw holes, the carb hat attachment holes, synch screws and idle speed bolt holes, the choke plunger seat holes, the Mikuni float valve seat bracket hole, the Hitachi float valve seat hole, Mikuni main jet needle retainer plate holes (inside the vacuum piston), all air jet and fuel jet holes, enrichment plunger lifter bracket holes, and throttle shaft butterfly valve mounting holes. NOTE: due to the expense of this kit, and the reality that you may use these tools only once, it is suggested that you use the tool rental option for this tap set. However, under the rental option, if you use the taps for actual thread tapping (cutting brand new threads in a newly drilled hole), then the return option is not allowed!
$ 149.95
HCP2398 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed uncoated steel. For use on all Mikuni idle mixture screw ports, and all Hitachi idle mixture screw ports with models using ultra-fine threaded idle mixture screws. NOTE: these threaded holes almost always need cleaning or re-tapping. Be careful when using these taps to make sure that you are cleaning and/or re-cutting the original threads, rather than any crossed/stripped threads that may be present. And beware the tiny needle tip hole at the bottom of the screw. Finally, note that the flat o-ring land (at the bottom of the screw hole) must not be damaged or gouged.......make sure that you do not run the tap in deep enough to damage that smooth land.
$ 12.95
HCP6335 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed uncoated steel. For the following holes:
- all Mikuni carb bowl drain screw hole.
$ 12.95
HCP6336 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed uncoated steel. For the following holes:
- all Hitachi and Mikuni throttle shafts where the butterfly valve screw on
- all models petcock faceplate mounting screw holes.
$ 9.95
HCP28202 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: Mikuni and Hitachi synch screw threads in the throttle shaft brackets, and Mikuni and Hitachi idle speed bolt threads in lower rack bracket.
$ 12.95
HCP2396 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes:
- Hitachi carbs air jet cover plate hold-down screw hole.
- Hitachi carbs "hat" hold-down holes.
- 1992-98 XJ600 Seca II Mikuni carb "hat" hold-down holes.
- XJ550, FZ600, YX600, and 1992-98 XJ600 Seca II Mikuni carbs bowl-to-body holes.
- XJ550, FJ600, FZ600, YX600, XJ650 Turbo, XJ700-X, XJ750-X, XJ900. XJ1100, and 1980-81 XS1100 Mikuni carbs float valve seat clamp hold-down screw.
- XJ550 and XJ650 gas tank emblem screw holes.
- All XJ-series original petcock vacuum diaphram cover plate and (some models) fuel outlet plate screws
- All XJ-series (except XJ750 Seca and XJ750 Euro models with cable-operated master cylinder) front and 1981 XS1100 Midnight Special front master cylinder cover hold-down screws.
- All XJ550, XJ650 (except Turbo), and XJ750 Seca original petcock fuel outlet cover plate screws.
NOTE: the carb hat threaded holes almost always need cleaning or re-tapping.
$ 9.95
HCP2397 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes:
- Hitachi upper rack mount screw holes.
- Hitachi float bowl mount holes in carb body.
- Hitachi pilot fuel jet hole in carb body.
- All models: gas cap mounting screw hole in all XJ-series gas tanks.
- Mikuni XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650 Turbo, XJ700-X, XJ750-X, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models carb "hat" screws.
- Mikuni XJ550, XJ700-X, XJ750-X, and XJ1100 carb choke bracket screw.
- Mikuni XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II, XJ650 Turbo, XJ700-X, XJ750-X, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models carb upper rack mount screws.
- Mikuni 1992-98 XJ600 Seca II carb lower rack mount screws.
- Mikuni XJ550 lower rack idle thumb screw bracket to lower rack bar.
- Mikuni FJ600, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, XJ1100, and XS1100 carb bowl-to-body screws.
- XJ1100 petcock drain screws.
- All XS1100 front master cylinder cover hold-down screws (except 1981 XS1100LH Midnight Special).
NOTE: the gas tank cap mounting hole almost always needs chased or re-tapped (be careful about this when buying a used gas tank!).
$ 9.95
HCP2399 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following threaded holes listed below, as well as many other areas of the bike. This 6 x 1.00 pitch is a very common sized thread.
$ 9.95
- Hitachi HSC32 air compensator jet holes.
- Hitachi lower carb rack mount screw holes.
- Hitachi pilot and main air jets port holes (in carb throat, below vacuum piston).
- Hitachi carb bowl drain screw hole.
- Mikuni XJ550, FJ/FZ/YX600, XJ600 Seca Ii, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, XJ1100, and XS1100 lower carb rack bracket screw holes.
- All models: gas tank mounting holes for the petcock.
- All models: gas tank fuel sending unit mounting holes.
- All XJ550 - XJ900 models cylinder head exhaust port stud holes.
- All XJ550 - XJ1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head cam bearing cap bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head intake manifold bolt holes.
- All XJ550 - XJ1100 and XS1100 models cylinder head valvecover mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine side covers mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine oil pan mounting bolt holes.
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolt holes (note: some of the mounting holes are different size, and require the use of the larger HCP11028 tap below).
- XJ700-X and XJ750-X cylinder heads and jugs coolant jacket bolt holes.
- Some models: cylinder head cam chain tunnel-to-cylinder jugs cinching studs, for engines that have 2 studs on both the front and rear of the tunnel (models with a single tunnel stud use the HCP11028 tap listed further below).
- Most models: upper crankcase to cylinder jugs stud.
- All models: cam chain tensioner mounting bolt holes.
- Some models: mechanical tachometer drive housing mounting hole.
HCP2400 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: Hitachi float valve brass seat hole, and Mikuni starter / enrichment circuit (“choke”) brass plunger seat hole on all XJ550, FJ600, FZ600, YX600, XJ600, XJ650 Turbo, XJ700-X, and XJ750-X carbs.
$ 14.95
HCP2401 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: Hitachi starter / enrichment circuit (“choke”) brass plunger seat bore hole.
$ 12.95
HCP28133 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes: Mikuni starter / enrichment circuit (“choke”) brass plunger seat bore hole on all XJ900, XJ1100, and XS1100 carbs.
$ 23.95
HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95
NOTE: always use a proper thread-cutting oil or lubricant before using thread taps! Thin motor oils work fine when merely doing a "clean-up" thread chase; a real cutting fluid should be obtained if a threaded bore needs to be truly cut:
HCP2402 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into aluminum or other soft metal. 4-ounce non-aerosol can.
$ 8.95
HCP2403 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into steel or other ferrous metals. 4-ounce non-aerosol can.
$ 8.95
c9a) Hitachi & Mikuni carbs THREAD CHASER DIES. Unlike the thread taps listed above, these thread DIES are used to clean, restore, and repair threads on the threaded fasteners (screws, bolts, studs, etc.). These tools help restore that like-new feel to used bolts, and straighten and restore threads to allow for proper torque settings to be achieved and maintained. Unlike standard round dies, these dies feature cutting teeth within a standard “hex-nut” shape, so you can use a wrench or socket to hold the die and turn it over the fastener. Just like cleaning / chasing threaded holes with a tap, this task is easy to use, important to do, and when you’re done you’ll be glad you took the time to do the job properly! NOTE: these dies are not used to cut new threads, only to renew threads on non-hardened fasteners! Always lubricate the tool (or fastener) with a light oil or grease when using.
HCP28566 Aftermarket THREAD CHASER DIE, for m3 x 0.50 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although nor a common size fastener--- it’s tiny! --- there are more applications than what is listed below). Each:
$ 6.95
- Hitachi and Mikuni butterfly shaft retaining screws.
- all models petcock faceplate screws.
- all models many control switch internal screws
HCP28567 Aftermarket THREAD CHASER DIE, for m4 x 0.70 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although nor a common size fastener, there are more applications than what is listed below). This is a very handy tool to have in your arsenal. Each:
$ 6.95
- Hitachi carb hat screws
- 1992-98 XJ600 Seca II carb hat screws
- All models: lower fork tube drain screws
HCP28568 Aftermarket THREAD CHASER DIE, for m5 x 0.80 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; this is a somewhat common size fastener and there are many more applications than what is listed below). This is a very handy tool to have in your arsenal. Each:
$ 6.95
- Mikuni carb hat screws (except 1992-98 XJ600 Seca II models)
- Hitachi and Mikuni carb upper rack bracket screws
- Mikuni lower rack bracket screws (1992-98 XJ600 Seca II models)
- Hitachi and Mikuni carb bowl mounting screws
HCP28260 Aftermarket THREAD CHASER DIE, for m6 x 1.00 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; this is a very common size fastener and there are many more applications than what is listed below). This is a very handy tool to have in your arsenal. Each:
$ 6.95
- Hitachi lower carb rack mount screws.
- Hitachi carb bowl drain screw.
- All models: gas tank mounting screws for the petcock.
- All models: gas tank fuel sending unit mounting bolts.
- Mikuni XJ550, XJ700-X, XJ750-X, and XJ1100 lower carb rack bracket screws.
- All XJ550 - XJ1100 models cylinder head valvecover mounting bolts.
- All XJ550 - XJ1100 and XS1100 models cylinder head cam bearing cap bolts.
- All XJ550 - XJ1100 and XS1100 models cylinder head intake manifold bolts.
- All XJ550 - XJ1100 and XS1100 models cylinder head valvecover mounting bolts.
- All XJ550 - XJ1100 and XS1100 models engine side covers mounting bolts.
- All XJ550 - XJ1100 and XS1100 models engine oil pan mounting bolts.
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolt holes (note: some of the mounting bolts are different size, and require the use of the larger HCP28261 die below).
- XJ700-X and XJ750-X cylinder heads and jugs coolant jacket bolts.
- Some models: cylinder head cam chain tunnel-to-cylinder jugs cinching studs, for engines that have 2 studs on both the front and rear of the tunnel (models with a single tunnel stud use the HCP28261 die listed below).
- Most models: upper crankcase to cylinder jugs stud.
- All models: cam chain tensioner mounting bolts.
- Some models: mechanical tachometer drive housing mounting bolt or stud.
- All XJ550 - XJ900 models cylinder head exhaust port studs.
- exhaust headpipe gas test port bolt fitted into the bottom of each header pipe.
- exhaust collector input (from header pipe) pinch clamp bolt (on models using the HCP2182 sized bolt).
- collector chrome cover retaining bolt (XJ1100 models)
- collector chrome cover rear retaining screw bolt (XJ1100 models)
- XJ650 Turbo models, for the right muffler “joiner pipe” mounting bolts.
- For any fasteners associated with the following fastener part number: HCP2182, HCP2264, HCP3572, HCP3926, HCP3933, HCP3935, HCP7107, HCP8351, and HCP8480.
HCP28582 Aftermarket SMALL THREAD CHASER DIES SET, contains one each of the most commonly used smaller sizes: HCP28567 (m4 x .70 pitch), HCP28568 ( m5 x .80 pitch), and the HCP28260 (m6 x 1.00 pitch) chaser dies.
$ 21.95
HCP28583 Aftermarket LARGE THREAD CHASER DIES SET, contains one each of the most commonly used smaller sizes: HCP28261 (m8 x 1.25 pitch), HCP28577 ( m10 x 1.25 pitch), and the HCP28579 (m12 x 1.25 pitch) chaser dies.
$ 23.95
HCP28585 Aftermarket COMPLETE THREAD CHASER DIES SET, contains all of the most commonly used sizes: one each of HCP28567 (m4 x .70 pitch), HCP28568 ( m5 x .80 pitch), and the HCP28260 (m6 x 1.00 pitch), HCP28261 (m8 x 1.25 pitch), HCP28577 ( m10 x 1.25 pitch), and the HCP28579 (m12 x 1.25 pitch) chaser dies. Note that XJ700-X or XJ750-X owners may also need to order the HCP28575 tap (m9 x 1.25 pitch) die separate in order to have a “complete” due set for those engines, as it is not included in this set.
$ 37.95
Carb Refinishing Tools:
Well, since you're going to spend the time and a lot of effort to make your carbs perform properly, why not also take them to "the final frontier"? Yes, performance is more important than appearance, but achieving a polished, "like-new" finish on your carb bodies is mostly just a labor of love, and time......rather than money.
Our special miniature POLISHING BRUSHES allow you to bring back the brilliant luster to the aluminum alloy carb bodies and bowls that makes them look showroom-fresh. Fitting into a standard high-speed dremel tool, these stiff bristle wire brushes not only remove the corrosion, discoloration, and oxidation that is typical of 30-year old carbs, but also leaves a smooth, sealed luster beauty that gives a truly professional touch to you restoration efforts.
These brushes can be used "as is", or, when combined with our coarse or fine-grit POLISHING POWDERS, makes the job that much easier and quicker. NOTE: in any case, plan on spending about 1-hour per carb to achieve a fully polished appearance.....it's tedious, but enjoyable, as you can easily see the progress as you go. ALSO.......perform the polishing procedure only after you have cleaned the carbs internally (via carb dip or other procedures), as many chemicals will react and dis-color the carb bodies!
As a final measure, we recommend spraying your newly polished bodies with our BULLETPROOF HIGH-GLOSS, 2-STAGE, FAST-DRYING CLEAR-COAT.....it's fuel resistant and non-yellowing, and will allow your labors of love to retain their beauty for many years to come.
HCP16662 Aftermarket miniature POLISHING BRUSH, 1/8" shank stainless steel bristle wire high-speed brush quickly removes corrosion and surface imperfections without displacing metal. Depending on how badly the carbs are tarnished, figure on using 2 brushes per carb body. NOTE: always wear eye protection when using these brushes, as they will tend to "shed" bristle fragments as they are used. Each:
$ 4.95
HCP16662SET8 Aftermarket miniature POLISHING BRUSHES, set of 8:
$ 32.95
HCP11198 Aftermarket BULLETPROOF HIGH-GLOSS, 2-STAGE, FAST-DRYING CLEAR-COAT WITH HARDENER. Requires 2-hours drying time to handle, and requiring just 18-24 days to fully cure. Once fully cured this clear-coat is chemical, oil, and fuel resistant, making it ideal for use on gas tanks, carbs, etc. NOTE: this clear coat is not rated for high-heat applications on engines, brake calipers, or brake rotors. 12-ounce spray can. 1 can will do a full set of carbs.
$ 24.95
DRIVETRAIN TOOLS:
NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:
http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630
and review the availability and procedures in the TOOL RENTAL section.
Clutch Tools:
HCP9237 Aftermarket clutch drum HOLDER TOOL. In order to install the clutch drum retaining nut HCP3204 above, you have to lock the clutch drum and prevent it from turning while the nut is torqued. Fits use with all XJ-series bikes. High quality, professional grade tool will last a lifetime.
$ 49.95
HCP10543 Aftermarket clutch drum HOLDER TOOL. In order to install the clutch drum retaining nut HCP3204 above, you have to lock the clutch drum and prevent it from turning while the nut is torqued. This tool uses a re-cycled drive plate to hold the basket while the nut is being removed or installed, thus spreading the load more evenly and equally than the HCP9237 tool listed above. Light-duty design is not recommended for shop use, but it works just fine for periodic (individual) use. Fits all XJ550, XJ650, XJ700, XJ750, and XJ900 models.
$ 29.95
HCP10530 Aftermarket standard-depth 30mm SOCKET, 1/2"-drive thick-wall impact socket necessary to remove or install the HCP3204 clutch hub nut. Black, 6-point, 1-/2" drive.
$ 13.95
HCP10300 Aftermarket 3/8"-to-1/2" DRIVE ADAPTER. For use with the HCP10298, HCP10299, HCP10530, HCP11336, HCP22025, or the HCP2222947 sockets, and the 10mm and 12mm HCP10302 stud extractors included in the HCP10301 tool kit. Most people have the standard 3/8" drive ratchet wrenches in their tool kits already, and the larger 1/2" drive sockets can be used with those ratchets with this converter/adapter. Chrome-plated, 1/2" male drive, 3/8" female receiver.
$ 12.95
HCP9972 Aftermarket precision CLICKER TORQUE WRENCH, 3/8" drive head, 20-200 inch-pounds (1.5 to 16 foot pounds), ratchet head and handle made of hardened steel for accuracy and durability. Scale is marked in both metric and SAE torque values for convenience. Comes in a plastic storage case. A good quality, affordable torque wrench for small fastener, low-torque applications. NOTE: please resist the temptation to "cheat" on low-value torque fasteners by using a high-value torque wrench (like the HCP9973 below) to set such fasteners. Torque wrenches, by their design, are only accurate within a certain range of torque values, and totally inaccurate above and below their designated range of values.
$ 69.95
Driveline Service Tools:
HCP9214 Aftermarket driveshaft REMOVER TOOL. Designed to be used with a slide hammer, this special "gear puller jaws" tool is designed to precisely fit around the large gear on the back end of the driveshaft and is used to "yank" and break the driveshaft free of the cross-joint splines, thus allowing the drive shaft to be removed through the rear of the swingarm. For all shaft-drive XJ-series bikes.
$ 89.95
HCP9211 Aftermarket middle drive gear SHAFT NUT REMOVAL SOCKET. Special thin, large diameter recessed hub socket needed to remove the bearing retaining nut on the middle drive gear. For use with all shaft-drive XJ-series except XJ1100 models.
$ 129.95
HCP9210 Aftermarket middle drive gear GEAR LASH MEASURING TOOL. For all XJ1100 models. This tool is designed to be used in conjunction with a dial indicator gauge.
$ 39.95
HCP9213 Aftermarket final drive input pinion gear PINION GEAR REMOVER ADAPTER TOOL. Designed to be used with a slide hammer, this special adapter screws onto the input gear shaft and then you can "bang" it out with a slide hammer tool. For all shaft-drive XJ-series bikes.
$ 69.95
HCP9291 Aftermarket final drive input pinion gear BEARING RETAINER WRENCH. The input shaft bearing is retained by a special retaining ring that requires this pegged drive socket to remove. For all shaft-drive XJ models except XJ1100 models.
$ 99.95
HCP9212 Aftermarket final drive input pinion gear coupler GEAR HOLDER TOOL, necessary for measuring and setting the gear lash correctly or for removing the final drive input shaft. For all XJ-series shaft-drive models.
$ 179.95
HCP9209 Aftermarket final drive output ring gear COLLAR, OIL SEAL, and ROLLER BEARING INSTALLATION AND REMOVAL TOOL SET, necessary for proper removal and installation of these parts. Set of two tools, one for removal and the other for installation. For all XJ-series shaft-drive models.
$ 149.95
dd2) Aftermarket camshaft and drive chain CHAIN BREAKER AND RIVETER TOOLS, needed to properly break and rivet a master link onto the replacement chains.
HCP26915 Aftermarket camshaft and drive chains CHAIN BREAKER AND RIVETER TOOL SET. A decent quality toolkit for occasional (home) use, it contains a complete set of 3 different size drive tips, a hollow-nose pin rivet tip, chain side plate press tool, alignment bolt and push bolt, handles, and special guide pin adapters, all contained within a durable plastic case. This kit can break cam, oil pump, and drive chains up to the # 630 size, press master link plates on chains up to # 530, and rivet hollow-nosed master link pins on chains up to # 630. It will not perform solid-nosed riveting. NOTE: most chain-drive XJ bikes of this era used size #520 or #530 drive chains (depending on model).
$ 89.95
HCP9203 Aftermarket camshaft and drive chains CHAIN BREAKER AND RIVETER TOOL SET, A professional quality tool designed for heavy-duty home or shop use. Contains a complete set of 3 different size drive tips, a hollow-nose pin rivet tip, chain side plate press tool, alignment bolt and push bolt, handles, and special guide pin adapters, all contained within a durable plastic case. This kit can break cam, oil pump, and drive chains up to the # 630 size, press master link plates on chains up to # 530, and rivet hollow-nosed master link pins on chains up to # 630. It will not perform solid-nosed riveting. NOTE: most chain-drive XJ bikes of this era used size #520 or #530 drive chains (depending on model).
$ discontinued
HCP9204 Aftermarket 2.2mm TIP for HCP9203 tool kit.
$ 9.95
HCP9205 Aftermarket 2.9mm TIP for HCP9203 tool kit.
$ 9.95
HCP9206 Aftermarket 3.8mm TIP for HCP9203 tool kit.
$ 9.95
HCP9207 Aftermarket WEDGE RIVETING TIP for HCP9203 tool kit.
$ 9.95
HCP9689 Aftermarket drive chain PULLER TOOL. This double-pin lateral puller hooks into two adjoining pins and allows a new, tight chain to be pulled together enough to allow the insertion of the master link.
$ 17.95
HCP9201 Aftermarket drive chain GRUNGE BRUSH. This unique design brush cleans all three sides of the drive chain on one pass. Fits all chain-drive bikes (and chain sizes) via an adjustable feature. Use with your favorite solvent.
$ 19.95
HCP9202 Aftermarket drive chain grunge brush REPLACEMENT PADS SET, for the HCP9201 brush listed above. Set of three replacement pads.
$ 7.95
HCP23864 Aftermarket drive chain GRUNGE BRUSH. This unique design brush cleans all three sides of the drive chain on one pass. Fits all chain-drive bikes (and chain sizes) via an adjustable feature. Use with your favorite solvent. Unlike the HCP9201 brush above, this version does not have replacable pads.
$ 16.95
ELECTRICAL TOOLS:
Electrical and Ignition System Tools:
NOTE: SOME OF THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: some tools are a one-time or infrequent use tool, so it may be more economical for you to rent them from us, rather than to purchase outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:
http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630
and review the availability and procedures in the TOOL RENTAL section.
General Electrical System Tools:
et1) Aftermarket electrical test MULTIMETERS, the most useful tool you'll ever own for working on electrical systems. These professional-grade test instruments make your life easier, and give you the accurate measurements needed to diagnose and track down electrical system issues.
Here are some good reviews that shows you how to use one to do various electrical system tests and troubleshooting:
http://nadp.sws.uiuc.edu/cal/PDF/MulltimeterUse.pdf
https://learn.sparkfun.com/tutorials/how-to-use-a-multimeter?_ga=1.238289411.262114863.1436923213
http://www.masonmonitoring.com/pdf/support/UsingMultimeter.pdf
https://learn.sparkfun.com/tutorials/how-to-read-a-schematic
http://www.autoshop101.com/forms/elec12.pdf
HCP7135 Aftermarket ANALOG (moving needle) MULTIMETER, more accurate than digital meters but a bit less user-friendly. These 6-function meters measure DC voltages (0-100), AC voltages (0-750), Resistance (0-10 megaohms), DC Current (0-10A), and has a small battery testing dial. NOTE: this multimeter does NOT have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event).
$ 79.95
HCP7136 Aftermarket DIGITAL (numerical LCD display) MULTIMETER, less accurate than analog meters but a bit more user-friendly. This 5-function meters measure DC voltages (0-1000), AC voltages (0-700), Resistance (0-2 megaohms), DC Current (0-10A), and Diode Checking. NOTE: this multimeter DOES have the capability to perform diode-checking, which can be a useful function when working on these bikes (although, to be honest, a diode failure is a rare event). Accuracy: DC voltage +/- 0.7%, AC voltage +/- 1.2%, DC current +/- 1%, Resistance +/-1%.
$ 69.95
HCP10589 Aftermarket TIMING LIGHT, inductive pickup 12V powered stroboscopic timing light is used to check the proper functioning of your ignition system at the pick-up coils. Alligator clips for easy power hook-up to the battery, and a clamp-over inductive feed clips over the #1 plug wire. Super-bright xenon-bulb makes daytime use possible.
$ 39.95
cps2) Aftermarket high-quality CROCUS CLOTH. Unlike sandpaper or emery paper, crocus cloth is a super-fine, cloth-backed soft abrasive that doesn’t “shed” particles during use, and is just the thing for burnishing and polishing of copper electrical contact, like the alternator rotor and starter motor commutators. Sold in a 2” wide x 1-foot long strip, enough for polishing many a commutator or contact.
HCP21378 Aftermarket strip of CROCUS CLOTH, measures 12” x 2”. Each:
$ 3.50
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP9762 Aftermarket miracle-goo black LIQUID ELECTRICAL TAPE is easier to use than traditional tape products, especially in close-in locations. Great for sealing crimped wire terminal ends to the wire and serves as a good alternative or supplement to shrink tubing. Just brush it on and let it dry! Comes in a 4-ounces brush-top can.
$ 6.95
HCP10508 Aftermarket electrical CONTACT CLEANER is a good general purpose cleaner and de-greaser. Will not harm plastic terminal connector blocks. Fast drying and leaves no residue. Comes in a 16-ounce aerosol can.
$ 8.95
Battery Tools and Testers:
HCP10448 Aftermarket battery testing HYDROMETER. This is a real hydrometer, not the cheapo 4-dollar special you usually see at the auto parts store. It measure the specific gravity of the electrolytic fluid, which is the proper way to test its condition. Those little "floating balls" testers are barely worth the plastic that they're made of! This professional hydrometer gives you temperature-adjusted specific gravity readings, which is the only accurate method of measurement. And yes, you can use these on your car or tractor or boat battery, too........
$ 12.95
HCP10542 Aftermarket battery testing MINI-HYDROMETER. This is a cheapy, "floating ball" style hydrometer, but it's small size makes it easier to use on motorcycle batteries. It's better than not having one at all! And yes, you can use these on your car or tractor or boat battery, too........
$ 7.95
fbc3) Aftermarket automatic BATTERY CHARGERS. A fully automatic battery charger is the best type to use to provide "trickle charge" to deep-cycle batteries, as it prevents the overcharge conditions that dramatically reduce the life of a battery.
HCP9962 Aftermarket automatic BATTERY CHARGER, standard bench-top style. Features that a 1.5A charger rate can be used to re-charge a dead battery quickly or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup protection, LED power-on/charging/charged indicator lights, CSA-certified, and comes with both 50A standard spring clamps or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 59.95
HCP28172 Aftermarket fully automatic BATTERY MAINTAINER-CHARGER. This compact wall-transformer style 6V and 12V charger features the latest solid-state, intelligent technology that allows quick, safe, and efficient charging of all battery types: conventional lead acid, maintenance-free lead acid, marine deep-cycle, AGM, gel-cell, and even lithium-ion. Features include: will safely charge even a fully dead battery (one that reads 0 volts), an automatic “de-sulphation” mode that can rescue and extend the life of older batteries, a thermal compensation sensor to prevent under- or over-charging, short-circuit protection, open-circuit protection, over-heat protection, over-charge protection, reverse-hookup protection, and spark protection. Can be hooked directly to the battery terminals with included ring terminals (a water-proof disconnect port is built into the 9-foot long lead wires), or you can use it with the included thin, “needle-nose” style clamps. Automatically changes from full-charge to float-mode monitoring for extended battery life and no worries about over-charging…..you can actually leave this charger hooked up to your battery 24/7 for as long as you want (like, all winter long……..) without risking battery damage (in fact, for all conventional lead-acid batteries, you should attempt to maintain it at 100% charge to maximize the battery life). Works on 110-240V AC current, 1-amp (max.15W) charging current, water-proof housing, 3-year warranty. This is most affordable and best “home-use” battery charger on the market/
$ 39.95
HCP28173 Aftermarket fully automatic BATTERY SUPER-CHARGER, all the same features as the HCP28172 above, but this charger feature more power output (2A, max. 30W charging current) and is a “mini-tabletop” design…..about 5.5” x 2.5”….no bigger than a typical computer mouse!
$ 69.95
HCP10449 Aftermarket automatic BATTERY CHARGER, compact wall-transformer style. Features that a 1.3A "pulse-mode" charger that can be used to re-charge a dead battery or maintain a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 79.95
HCP10451 Aftermarket automatic BATTERY MAINTENANCE CHARGER, compact wall-transformer style. Features that a 800ma (0.8A) charger rate, perfect for maintaining a trickle-charge for batteries that see infrequent use. Automatically changes from full-charge to float-mode monitoring for the extended battery life and no worries about over-charging. Reverse-hookup and short-circuit protection, LED power-on/charging/charged indicator lights, waterproof, and comes with both alligator clips or the easy-to-use permanent plug-in connector to permanently attach a charging "pigtail" connector to the battery for instant access. No bigger than a typical computer "mouse"! Can be safely used on conventional and AGM style batteries; not recommended for gel-cell batteries.
$ 59.95
HCP10452 Aftermarket battery charger EXTENSION CABLE, 12-foot length. Don't want to bring your bike over to your charger? Then this set of 12-foot long charger-to-battery leads extender cable allows you to leave the battery charger close to a wall outlet, and extend the power leads to wherever your bike is located! Quick-connect feature allows plug-and-play installation with all of the above chargers. Very convenient.
$ 19.95
et3) Aftermarket motorcycle-sized BATTERY JUMPER CABLES. Small sized end clips more easily reach into the cramped areas where your battery lives, making it somewhat easier to jump-start a dead bike. NOTE: NEVER attach jumper cables to your battery unless your ignition key is OFF......or your risk frying a lot of expensive electrical components!
HCP1608 Aftermarket 5-foot long standard duty JUMPER CABLES, with alligator clip ends.
$ 29.95
NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the postal Priority Mail, postal Express Mail, or private carrier Expedited levels of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Additionally, there may be a per-package weight or quantity restriction, and thus multiple-unit orders of this product may have to be shipped in separate packages and will incur additional shipping charges.
HCP10493 Aftermarket battery post TERMINAL SEALER helps keep corrosion from forming on the battery terminals. Fast drying and leaves no residue. Comes in a 6-ounce aerosol can.
$ 5.95
HCP10540 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery box with a sharp knife or a pair of scissors. For all XJ550, XJ650, XJ700, XJ750, and XJ900RK models.
$ 4.95
HCP10541 Aftermarket acid-neutralizing BATTERY MAT, thin felt mat with pressure-treated with a battery-acid neutralizing chemical. Easily placed directly under the battery, it prevents any spills or discharge from the battery from doing damage to your paint, frame, etc. Trim to fit your battery tray with a sharp knife or a pair of scissors. For all XJ1100 models.
$ 5.95
Spark Plug Tools:
HCP8674 Aftermarket deep-reach thinwall SPARK PLUG SOCKET, copy of the original tool used on XJ550 and 1984-85 FJ600 models. Includes the short "breaker bar".
$ 9.95
HCP9721 Aftermarket deep-reach thinwall SPARK PLUG SOCKET, copy of the original tool used on all XJ650, XJ700 air-cooled, all XJ750 air-cooled, XJ900RK, RL, N, F, and FN models, and all XJ1100 models. Includes the short "breaker bar".
$ 9.95
The following aftermarket PLUG SOCKETS are special deep-reach, thin wall design tools that are specially designed to allow use on XJ700-X and XJ750-X models, where the spark plug lives deep inside a recessed well on the cam cover. Typical plug socket tools are far too big in their outside diameter to fit into this well. Although not necessary, these sockets will also work fine on all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, and XJ900 S/SH model spark plugs also.
HCP9691 Aftermarket deep-reach thinwall SPARK PLUG SOCKET, copy of the original tool used on all XJ700-X water-cooled and XJ750-X water-cooled models models. Has a 17mm hex at the top end of a tool to accept a socket or wrench.
$ 11.95
HCP8552 Aftermarket deep-reach thinwall SPARK PLUG SOCKET, 3/8" square drive, needs to be used with a 3" extension to clear the valve cover on all "X" models.
$ 16.95
HCP9123 Aftermarket 3" socket EXTENSION BAR, chrome plated, 3/8" drive, for use with the HCP8552 socket above. Each:
$ 6.95
HCP8430 Aftermarket deep-reach thinwall SPARK PLUG SOCKET, 3/8" square drive, 13/16" hex wrench drive, or can be used with a straight round breaker bar, requires the use of a 1"-to-1.75" extension to clear the valve cover on all "X" models.
$ 21.95
HCP9124 Aftermarket 1-3/4" socket EXTENSION BAR, chrome plated, 3/8" drive, for use with the HCP8430 socket above. Each:
$ 5.95
HCP28131 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed uncoated steel. For the following holes:
- 12mm spark plug holes on all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600, XJ700-X, XJ750-X, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 and 1988 FZ750, 1987 FZR750R, and 1987-88 FZR1000 engines. This deep-reach tap has a socket-drive head for constricted-space clearance, and will allow access to the plug hole even in the recessed XJ700-X / XJ750-X heads.
$ 23.95
HCP6378 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed uncoated steel. For the following holes:
- 14mm spark plug holes on all XJ650, XJ700 air-cooled heads, all XJ750 air-cooled heads, XJ900, XJ1100, and all XS1100 engines. For use by hand or with a 13/16" socket. Each:
$ 13.95
HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95
NOTE: always use a proper thread-cutting oil or lubricant before using thread taps! Thin motor oils work fine when merely doing a "clean-up" thread chase; a real cutting fluid should be obtained if a threaded bore needs to be truly cut:
HCP2402 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into aluminum or other soft metal. 4-ounce non-aerosol can.
$ 8.95
HCP2403 Aftermarket machinist-grade professional THREAD CUTTING FLUID, for use when cutting into steel or other ferrous metals. 4-ounce non-aerosol can.
$ 8.95
spt22) Spark plug drain well BRUSH and BLOCK-OFF PLUGS allow you to clean out the water-drain wells in the cylinder heads on all XJ700-X and XJ750-X (water-cooled) engines. These drain passages are only accessible by removing the cylinder head decorative, ribbed side covers (which will expose the small, center well drain-hole on the side of the head). This passage hole is used to drain water and associated grit and gunk from the spark plug wells on each side of the head (i.e. the left side hole drains plugs #1 and #2; the right side hole drains wells on the #3 and #4 plugs). Clogged drain ports allow water and other junk to build up in the plug wells, with predictable results. Our extra-long WIRE-BRISTLE BRUSH is the correct size and depth to purge these passages, while the BLOCK-OFF PLUGS replace the spark plugs while the cleaning procedure is being performed (the spark plugs must be removed to allow the brush clearance to pass all the way thru the passage).
The procedure to clean these wells ---- which, by the way, is not mentioned at all in the service manual ---- is as follows:
1) remove the decorative head side cover.
2) remove the spark plug cap/boot…….leave the spark plugs in for now.
3) using compressed air, blow out any debris in the wells.
4) remove the two spark plugs on that “side” of the head you are working on.
5) install the low-profile block-off plugs into the two spark plug holes.
6) use the wire-bristle brush to clean out the drain passage completely. Any debris will be “pushed” into the plug wells (that’s why you need to install the block-off plugs!).
7) using compressed air, blow out any debris in the wells.
8) remove the low-profile block-off plugs, and re-install the spark plugs, plug cap/boot, and decorative side cover.
9) repeat steps 1-8 for the other side.
10) this procedure should be done once every few years or so.
HCP21394 Aftermarket STAINLESS STEEL WIRE-BRISTLE CLEANING BRUSH, perfect size for cleaning out the spark plug well drain passage in the cylinder head of all the built-up gunk and debris. For use on all XJ700-X and XJ750-X engines..
$ 8.95
HCP21367SET2 Aftermarket spark plug hole BLOCK-OFF PLUGS, these low-profile plugs are the correct size to replace the spark plugs while cleaning out the spark plug well drain passage in the cylinder head. For use on all XJ700-X and XJ750-X engines.. Set of 2 plugs:
$ 11.95
HCP21998 Aftermarket spark plug well drain passages CLEAN-OUT KIT, contains the HCP21394 brush and two of the HCP21367 plugs, everything you’ll need to perform the cleaning procedure.
$ 15.95
HCP20451 Aftermarket spark plug wire terminal CRIMPING TOOL. This basic, 7-function hand-crimp tool incorporates wire butter, terminal crimper, and wire stripper functions into one handy tool. Black anodized finish with insulated hand grips, crimp slot on end of tool secures most ignition terminals including "W" type, right angle and "High Tower" terminals. Will crimp 7mm to 8.5mm plug wire, and works with 10- to 22-gauge solderless terminals.
$ 39.95
HCP9739 Aftermarket spark plug wire terminal CRIMPING TOOL. This high-quality, professional grade ratcheting tool is easy-to-use feel, but will still achieve a complete and thorough crimp of the wire terminals to the plug wire, preventing future separation or electrical resistance issues. The right tool for the job makes life easier......
$ 89.95
Neutral Switch Tools:
NOTE: THE FOLLOWING TOOLS ARE AVAILABLE FOR RENTAL!!: since this tool is a one-time or infrequent use tool, it may be more economical for you to rent it from us, rather than to purchase it outright. Please see the “rental” section within the THE TOOLBOX section of our catalog at:
http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630
and review the availability and procedures in the TOOL RENTAL section.
HCP15718 Aftermarket neutral position switch REMOVAL SOCKET. On many models, it's almost a physical impossibility to remove the HCP443 (or the aftermarket version, HCP15671) neutral switch from the crankcase "well" without removing the exhaust system or removing the engine from the frame.....the left lower frame tube conspires with the exhaust system to make it unbelievably difficult to access the switch. This special "open side" socket is the proper size to squirm through those restricted spaces and make it possible to remove and re-install the position switch without going through a tremendous amount of effort. Standard 1/4" drive socket should be used with a 3" extension bar, or, it's even easier to use when attached to the HCP13516 flexible shaft driver listed below. NOTE: this tool will not help you on XJ650 Maxim models with the stock exhaust system, as the crossover pipe is in the way and prevents access of even this tool.
$ 21.95
HCP13516 Aftermarket flexible "spring shaft" 1/4" SOCKET DRIVER TOOL, just the thing to use with the HCP15718 socket above to reach the neutral switch. Large plastic handle with 6" long flexible shaft.
$ 19.95
Alternator Tools:
ap7) Aftermarket alternator ROTOR REMOVAL TOOLS, correct copy of the factory Yamaha tool needed to remove the alternator rotor from its mounting shaft (the rotor is a friction fit onto the tapered end of the alternator shaft). Designed to be used in conjunction with the HCP6495 rotor puller tool Attachment Tool listed below. The use of these two tools allows you to safely and properly remove your rotor without damaging either the rotor or the rotor shaft. For all XJ550 thru XJ1100 models.
HCP1404 Aftermarket ROTOR REMOVAL TOOL, screws into the threaded hub of the alternator, heavy-duty shop-grade tool.
$ 17.95
HCP21905 Aftermarket ROTOR REMOVAL TOOL, screws into the threaded hub of the alternator. Less expensive version than the shop-grade version tool HCP1404.
$ 11.95
HCP6495 Aftermarket ROTOR REMOVAL ATTACHMENT, slides into the end of the internally threaded alternator shaft and prevents the tip of the HCP1404 from "mushrooming" the end of the shaft.
$ 5.95
HCP10236 Aftermarket TORX-DRIVE SOCKET, fits standard 3/8"-drive ratchets. Has the proper size torx-driver bit included. NOTE: this socket can be used with a 3/8" drive impact driver (such as our HCP9706 impact wrench set) but it is not rated for impact wrench use. However, since you will most likely only be using the bit one time (to loosen the 3 bearing housing screws), then you should be able to accomplish the task, and purchase a replacement bit if necessary.
$ 14.95
HCP10237 Aftermarket replacement TORX-DRIVE BIT, fits the above socket.
$ 4.95
WIRE ASSEMBLY and SOLDERING TOOLS:
Wire Cutter, Stripper, and Terminal Crimper Tools:
These professional-grade tools put the discount chain-store variety to shame. If you want strong and secure connections when you're done, don't try to save a few dollars on inferior quality tools. There's absolutely nothing more frustrating than have a wire stripper that pulls the wire strands out (along with the insulation) because it's pivot point won't hold a setting, or because the round holes were not cut to the proper depths. And terminal crimper tools that have an incorrect or poor tolerance profile just won't ever crimp tightly enough, and then the wire will pull out of the terminal crimp----no matter how hard you squeeze!
Proper wire terminal installation techniques can be reviewed at:
http://www.xj4ever.com/crimping my style.pdf
and here’s how to properly solder a connection:
http://advrider.com/forums/showthread.php?t=281500
HCP13112 Aftermarket standard-duty WIRE CUTTER and STRIPPER TOOL. Designed for 10-22 gauge stranded copper wire only, this tool features precision-cut holes for wire insulation stripping, as well as high-carbon steel precision scissors-type blades for straight-cut, flush end wire cutting. Highly visible AWG and mm wire gauge sizes are embossed into the handle as well as color-coded. The tapered end of the base allows you to pull and twist frayed wire ends back into a tight strand. Soft comfort handles.
$ 21.95
HCP13113 Aftermarket heavy-duty WIRE CUTTER and STRIPPER TOOL. Designed for 12-20 gauge stranded copper wire only, this tool features precision-cut holes for wire insulation stripping, as well as stainless steel, nick-resistant scissors-type blades for straight-cut, flush end wire cutting. AWG wire gauge sizes are embossed into the handle. The tapered end of the base allows you to pull and twist frayed wire ends back into a tight strand. Curved, soft comfort-grip handles.
$ 39.95
HCP13223 Aftermarket heavy-duty WIRE CRIMPER, STRIPPER, and CUTTER TOOL, professional grade for use with original style "open-barrel" wire terminals. Although this crimper is not a ratchet-design, its long lever arms produce enough force to properly secure the wire to the terminal, vastly simplifying its use and performance. For 14-22 gauge wire terminals.
$ 109.95
HCP13065 Aftermarket heavy-duty WIRE CRIMPER TOOL, designed for use with original style "open-barrel" wire terminals. This crimper is a ratchet-design that will not release until the crimp is fully completed, vastly simplifying its use and performance. For 12-22 gauge wire terminals.
$ 69.95
HCP14583 Aftermarket super-duty WIRE CRIMPER TOOL, for use with original style "open-barrel" wire terminals. This crimper is a ratchet-design that will not release until the crimp is fully completed. For 12-22 gauge wire terminals. A professional level tool, combines ease of use while achieving crisp and consistent final crimp quality.
$ discontinued
HCP13066 Aftermarket heavy-duty WIRE CRIMPER TOOL, designed for use with aftermarket style "closed-barrel" wire terminals (such as with butt connectors, or other style terminals with a hollow metal receiver tube that the wire fits into before crimping). This crimper is also a ratchet-design that will not release until the die set if fully closed, and thus the crimp is fully completed. For 10-22 gauge wire terminals.
$ 59.95
Terminal Removal Tools:
Once a wire-end terminal is inserted into its connector shell, a small metal "spring-tab" or "tongue" locks the terminal into a recess in the connector shell, thus preventing the terminal and wire from coming back out of the shell. Think of it as the terminal equivalent of the barb on the end of a fish-hook----easy going in, not so easy to get back out......
Of course, if you want or need to extract a terminal from its connector shell....for repair or replacement, for instance.....then you'll find the use of these TERMINAL REMOVAL TOOLS to be greatest thing since sliced bread. Proper width flat spring-steel blades formed into a rising wedge shape allows you to quickly and easily depress the spring-tab "hook" back up and into the terminal, thus "un-locking" the locking tab from the connector shell, and a quicky tug on the wire now releases the terminal from the shell. Works on all small, medium, and wide flat-blade style terminals only! Not for use on the round pin terminals.
HCP15686 Aftermarket small flat-blade TERMINAL REMOVAL TOOL, round plastic handle for ease of use.
$ 17.95
HCP15687 Aftermarket medium and large flat-blade TERMINAL REMOVAL TOOL, round plastic handle for ease of use. On some connector shells, this tool can also be used to release the small flat-blade terminals, too.
$ 19.95
Wire Solder and Soldering Guns:
While there is a unbelievably confusing array of solder choices, we've narrowed your choices down to one brand and type that we feel is the best: 3.5% SILVER BEARING, LEAD-FREE, ROSIN-CORE SOLDER. Let's go over those features one at a time:
a) Silver is the best material to use for small-wire electrical soldering, due to both the high-strength of silver and the exceptional electrical conductivity of silver (as opposed to lead solder).
b) Lead is a poisonous substance, and the soldering process has the potential to release lead fumes into the air....and into your eyes and lungs.....and that's just not a good thing, at all.
c) In the old days, solder was "pure" solder (be it lead-based, silver, etc.) and the cleaning flux was a separate material that had to be applied by hand. Modern "solder" is available with a central, internal flux core so that the cleaning and de-oxidizing properties of the flux----which has a lower melting point than the solder itself----is released and performs the cleaning task on the wires and terminals immediately before the solder itself melts and flows. The miracles of modern technology at its best..........
NOTE: never use acid-core solder or an acid-based flux when performing electrical wire soldering!
Of course, you'll want to apply such solder with a professional-quality SOLDER GUN, and since you probably, just like the rest of us, only have two hands, then you'll quickly come to appreciate our super-handy WIRE HOLDER tool that allows you to clamp the wires properly in place before soldering, leaving your hands free for the solder feed and the handling of the gun.
HCP13067 Aftermarket standard-duty SOLDERING GUN SET, 120-volt, dual 100-Watt and 140-Watts power settings, tip temperatures of 900-F and 1020-F. An excellent 8-piece kit which includes the gun, the tin-plated copper soldering tip, a plastics heat-cutting tip, a flux brush, all enclosed in a hard-shell protective carrying case.
$ 57.95
HCP13068 Aftermarket heavy-duty SOLDERING GUN SET, 120-volt, dual 200-Watt and 260-Watts power settings, tip temperatures of 900-F and 1100-F. An excellent 8-piece kit which includes the gun, the tin-plated copper soldering tip, a plastics heat-cutting tip, a flux brush, all enclosed in a hard-shell protective carrying case.
$ 69.95
HCP13108 Aftermarket 3.5% SILVER BEARING, LEAD-FREE, ROSIN-CORE SOLDER, 15-foot spool contains enough material to solder many, many wire joints! 430-F solder melt temperature, .032" diameter solder wire size is just right for the type of wires you'll be working on.
$ 9.95
HCP13111 Aftermarket magnetic WIRE HOLDER - CLAMPS TOOL, a very useful gadget when trying to manipulate 2 (or more) wires and trying to solder at the same time. Adjustable spring-loaded alligator clips hold the wires steady and in alignment while you do the soldering; both the tool base and the clips are magnetic so that you can the tool on a metal surface without it walking, or the hex-shaped tool base allows it to be clamped into a vice for complete restraint of movement. You'll be glad your bought it!
$ 23.95
Wire Harness Tape:
Factory wire harness bundles were taped with a black electrically-insulating protective VINYL ELECTRICAL TAPE WRAP to provide both an orderly routing of the main harness wires and for additional wire protection. We have the correct 19mm wide black, high-voltage, adhesive-backed, all-weather stretch tape to allow you to repair or re-tape your harness. NOTE: XJ750 Maxim models that used this hard-shell, plastic ribbed tubing to protect the wire bundles had the hard-shell tubing externally wrapped with this tape.
HCP12923 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 20-foot roll.
$ 4.95
HCP13134 Aftermarket harness bundle VINYL ELECTRICAL TAPE WRAP, black, 66-foot roll, almost enough to do one complete harness.
$ 10.95
Additionally, most harnesses had a few short turns of COLORED VINYL ELECTRICAL TAPE WRAP to provide visual identification of "what connector goes where?" during harness assembly and installation. Always located just by the connector shell, about 3-4 turns of this tape was used to both tape off any vinyl sleeve and to properly identify what the connector plugged into. Used primarily at the TCI connector (from the pick-up coils) and at the various small "cube" style relays (headlight relays, sidestand safety switch relays, etc.). Since all of these harness connector shells are the same style and type (4-position, horizontally oriented 2-over-2), this small tape wrap served as a way of indicating which of these many identical connectors went to which component.
HCP13130 Aftermarket harness bundle YELLOW VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on XJ700-X and XJ750-X models, and at the headlight relay connector on all XJ550 models, all XJ650 (except Turbo) models, and all XJ750 Seca models.
$ 3.95
HCP13131 Aftermarket harness bundle RED VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on 1982-83 XJ650 Maxim models, all '81-83 XJ750 models, and all XJ700 non-X models, and at the fuel pump relay connector on all XJ650 Turbo models.
$ 3.95
HCP13132 Aftermarket harness bundle BLUE VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ550 models, at the emergency stop switch relay connector on all XJ650 Turbo models, and for the sidestand safety switch relay connector on all XJ550 models, all '82-83 XJ650 models, all XJ750 models, XJ900RK and XJ1100 models.
$ 3.95
HCP13133 Aftermarket harness bundle GREEN VINYL ELECTRICAL TAPE WRAP, 20-foot roll. Used by the pick-up coil harness connector (at the TCI) on all XJ650RJ Seca and XJ1100 models.
$ 3.95