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SECTION H:
CLUTCH/TRANSMISSION/DRIVETRAIN:
--Transmission and Middle Gear
TRANSMISSION:
Hopefully, you're reading this section of the catalog just out of intellectual (or morbid) curiosity, and not because you have a transmission problem.....which in fact, is pretty rare with these XJ series engines (except, perhaps, on the XJ1100 models). The trannies are pretty bulletproof, and many "shifting" problems or issues are really caused by worn or improperly adjusted clutch system components, shifter mechanism issues, or shifter drum (the infamous disintegrating primary chain guide problem).
However.........that's not to say that they are infallible, especially on very high-mileage or improperly operated or maintained bikes. Indeed, bikes that jump out of gear, or that won't stay in gear or even go into gear, may be suffering from worn gear "dogs" or "slots" which, taken together, are what act to synchronize and "lock" two gears together while in operation, and thus can cause all sorts of problems when worn.......due to rapid shifting, forceful shifting, or extreme high-torque shifting events.
If you've determined that your transmission problems are caused by gear or fork issues, and feel up to the task, then we can still provide you with some of these GEARS, SHIFT FORKS, and HARDWARE that you'll need. Be aware that while you can replace some of these items with the engine still in the bike, it's a tricky proposition, at best. You really should resign yourself to the fact that the engine needs to come out, the crankcase halves need to be split, and as long as you're doing that level of surgery, you might as well do a partial or full engine rebuild at the same time.............
To add a little more confusion to the whole mix, when you have these types of problems, although they typically manifest themselves on 1st gear (won't go into it) or 2nd gear (won't go in, stay in, or jumps out of), it's not always a problem with the actual "1st Gear" or "2nd Gear" set. Because of the way that these transmissions operate, it may be that the problem is actually caused by the 4th GEAR itself, since the "slots" are on the 1st Wheel Gear and the "dogs" are on the 4th Pinion Gear.......and the interaction of those two gears is what actually puts the transmission in "1st gear".
Confused yet? We certainly hope so, it means you're paying attention! For further information, we suggest you start by watching this remarkably understandable and entertaining video. Coming to you straight from 1936, this short Chevrolet promo video “Spinning Levers” is the simplest explanation of what “gearing” actually is and how a transmission works:
With the above understanding, you can then read this extremely well-written article.....although written by and for XS1100 owners, the exact same principles and circumstance apply to all of the XJ-series transmissions:
https://xs11.club/forum/repairs/transmission-aa/5292-1st-and-2nd-gear-dremmel-fix-part-1-2-and-3
Further comprehension can be achieved by reviewing this pictorial guide about how XJ transmissions operate:
https://xs11.club/forum/repairs/transmission-aa/211-xs11-transmission-pictures-and-explanation
And here is a really great (somewhat long, but at least the chap is funny and entertaining) showing you what “dogs” and “slots” are, how they affect the operation of the gearbox, and showing you a damaged tranny gear set, explains what happened, and how/why what needs to be replaced. Eventually, you’ll have an excellent working understanding of gearbox issues, what happens and what can go wrong (and why you shouldn’t ever “power shift” or slam the tranny from first to second…..unless, of course, you actually enjoy rebuilding sequential transmissions):
These two fantastic videos show how power gets from your crankshaft, thru the clutch and transmission, and onto to the rear wheel. Although the animations show a chain-driven bike transmission (much like an XJ550 or any of the XJ600 models), the same concepts apply to shaft-driven bikes. Understanding how these seemingly “voodoo” parts operate and interact with each other can help make troubleshooting and repair much simpler.
I’d suggest watching both of them, in the following order (although it may seem “backwards”) to get the best understanding:
How the shifter mechanism and transmission works (and transmits power to the rear wheel):
How the clutch works (and transmits power to the transmission)….shown on 1100 engines; again, just like all of the others work:
https://www.youtube.com/watch?v=JhTf7cBeGcs
And here’s an un-animated versions, to show you “the real thing”:
https://www.youtube.com/watch?v=TKkInvmWrtc
Okay, so if your transmission is suffering from any of these problems, then typically this is what the underlying problems are:
FIRST GEAR PROBLEMS:
* bike didn't seem to want to slide into first gear:
The dogs on the 4th pinion gear and slots on the 1st wheel gear can get worn quite significantly (as well as the number 3 shift fork) when wear occurs to these parts, and the previous owner(s) have been holding their foot down on the shift lever during acceleration to keep the bike in first gear. The gears get worn, and the rider compensates by holding the bike in gear by applying pressure to the shifter pedal, which then damages the shift fork itself.
The wear on these items appear to occur most during shifts from neutral to first at a standing position, and during direct 2nd-to-1st gear shifts during deceleration when the shift occurs at too fast of a speed.
Note that these gears are located on the "output shaft" or "countershaft" as it is sometimes referred to.
Solution: replace the worn 1st wheel gear, the worn 4th pinion gear, the shifter fork, or any combination of the three.
SECOND GEAR PROBLEMS:
* the infamous "jumping out of 2nd gear" problem is due to a poor contact area between the dogs on 5th wheel gear, and slots on 2nd pinion gear, both located on the main (or input) shaft (the main or input shaft is the shaft that the entire clutch assembly is bolted to).
Solution: replace the worn 2nd pinion gear or the worn 5th wheel gear, or both.
How to: here’s the procedure, as shown on an XS1100 (same for an XJ1100, and kind of similar on other models, although, this problem is much more common on the liter bikes than the smaller ones):
https://www.youtube.com/playlist?list=PLwYMGfqlQ5KpUWAEQzUDycK5YXs1o2Rxy
And if at first you don’t succeed…….”it’s shifts like a Russian tractor”:
https://www.youtube.com/shorts/PEh8rK1g9oE
Of course, some of these issues may be due to something as simple as broken shifter mechanism SPRINGS (see the INTERNAL SHIFTER MECHANISM PARTS:section further above for details) or the dreaded "disintegrating primary chain guide" issue, and it's always best to determine whether a simple problem exists first, before digging into the bowels of the engine case..........
And here’s some good videos showing the proper method of installing ball bearings into engine cases and onto shafts:
and
XJ550 and FJ600 engines:
- the following "pinion" gears and hardware components are located on the main axle shaft (or "input shaft"):
HCP7326 OEM input/main axle shaft 2nd PINION GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1982-83 XS400 RJ/RK engines.
$ 129.95
HCP7325 OEM input/main axle shaft 6th PINION GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian engines.
$ 189.95
HCP7327 OEM input/main axle shaft BEARING, right end, use on all XJ550 and 1984-85 FJ600 engines.
$ 64.95
HCP7330 OEM input/main axle shaft BEARING, left end, use on all XJ550 and 1984-85 FJ600 engines.
$ 42.95
HCP7322 OEM input/main axle shaft SPACER WASHER, fitted between the 3rd and 4th/5th pinion gears on all XJ550 and 1984-85 FJ600 engines.
$ 6.95
HCP7323 OEM input/main axle shaft CIRCLIP, fitted between the 3rd and 4th/5th pinion gears on all XJ550 and 1984-85 FJ600 engines.
$ 7.95
HCP7328 OEM input/main axle shaft HALF-CIRCLE CLIP, fitted outside of the bearing at the right end of the shaft on all XJ550 and 1984-85 FJ600 engines.
$ 19.95
HCP7331 OEM input/main axle shaft CIRCLIP, fitted at the left end of the shaft on all XJ550 and 1984-85 FJ600 engines.
$ 7.95
HCP7332 OEM input/main axle shaft OIL NOZZLE, fitted at the left end of the input shaft on all XJ550 and 1984-85 FJ600 engines.
$ 8.95
- the following "wheel" gears and hardware components are located on the output drive axle shaft (or "output shaft"):
HCP7344 OEM output shaft 1st WHEEL GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1982-83 XS400 RJ/RK engines.
$ 239.95
HCP7335 OEM output shaft 2nd WHEEL GEAR, for all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, and 1982-83 XS400 RJ/RK engines.
$ 149.95
HCP7339 OEM output shaft 3rd WHEEL GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1982-83 XS400 RJ/RK engines.
$ 149.95
HCP7340 OEM output shaft 4th WHEEL GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and 1982-83 XS400 J/RJ/RK engines.
$ 149.95
HCP7343 OEM output shaft 5th WHEEL GEAR, for all XJ550 and 1982-83 XS400 J/RJ/RK engines.
$ 229.95
HCP7338 OEM output shaft 6th WHEEL GEAR, for all XJ550, 1984-85 FJ600, 1986-88 FZ600, and 1986-90 YX600 Radian engines.
$ 149.95
HCP7330 OEM output shaft BEARING, right end, use on all XJ550 and 1984-85 FJ600 engines.
$ 42.95
HCP7780 OEM output shaft BEARING, left end, use on all XJ550 and 1984-85 FJ600 engines.
$ 57.95
HCP7322 OEM output shaft SPACER WASHER, fitted between the 4th and 5th wheel gears on all XJ550 and 1984-85 FJ600 engines.
$ 6.95
HCP7336 OEM output shaft SPACER WASHER, fitted to the left of the 2nd wheel gear on all XJ550 and 1984-85 FJ600 engines.
$ 6.95
HCP7345 OEM output shaft SPACER WASHER, fitted to the right of the 1st wheel gear on all XJ550 and 1984-85 FJ600 engines.
$ 7.95
HCP7323 OEM output shaft CIRCLIP, fitted between the 4th and 5th wheel gears on all XJ550 and 1984-85 FJ600 engines.
$ 7.95
HCP7328 OEM output shaft HALF-CIRCLE CLIP, fitted between the oil seal and the bearing on the left end of the shaft on all XJ550 and 1984-85 FJ600 engines.
$ 19.95
HCP7331 OEM output shaft CIRCLIP, fitted at the right end of the shaft on all XJ550 and 1984-85 FJ600 engines.
$ 7.95
HCP7332 OEM output shaft OIL NOZZLE, fitted at the right end of the output shaft on all XJ550 and 1984-85 FJ600 engines.
$ 8.95
XJ550 shifter forks:
HCP8493 OEM shifter fork slider bar retaining bracket COUNTERSUNK SCREW, use 1 per engine, torx-drive, fits all XJ550 engines, each:
$ 7.95
HCP22177 Aftermarket shifter fork slider bar retaining bracket COUNTERSUNK SCREW, use 1 per engine, torx-drive, fits all XJ550 engines, each:
$ 4.95
The above screw is the shift fork guide rod retainer bracket screw. There is also another "screw" (actually a threaded stud) which has a central nut, and one side of the stud is threaded, while the other side has a smooth shank:
HCP5068 OEM shifter fork slider bar STOPPER STUD ("SCREW"), use 1 per engine on all XJ550 engines, each:
$ 14.95
HCP506 OEM shifter fork slider bar stopper stud LOCKWASHER, use 1 per engine, phillips-drive, fits all XJ550 engines, each:
$ 4.95
XJ650, XJ700, XJ750, and XJ900RK engines:
- the following "pinion" gears and hardware components are located on the main axle shaft (or "input shaft"):
HCP7774 OEM input/main axle shaft 4th PINION GEAR, for all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 129.95
HCP7776 OEM input/main axle shaft 5th PINION GEAR, for all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 159.95
HCP7778 OEM input/main axle shaft BEARING, left end, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, and N/FN engines.
$ 39.95
HCP19257 Aftermarket input/main axle shaft BEARING, left end, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, and N/FN engines.
$ 24.95
HCP13940 OEM input/main axle shaft BEARING, left end, used in XJ900F engines.
$ 29.95
HCP19280 Aftermarket input/main axle shaft BEARING, left end, used in XJ900F engines.
$ 19.95
HCP7780 OEM input/main axle shaft BEARING, right end, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 57.95
HCP7322 OEM input/main axle shaft SPACER WASHER, fitted between the 2nd/3rd pinion gears and the 4th pinion gear on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 6.95
HCP7345 OEM input/main axle shaft SPACER WASHER, fitted to the left end of the shaft, just inside the support bearing, on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 7.95
HCP7323 OEM input/main axle shaft CIRCLIP, fitted between the 2nd/3rd and 4th pinion gears on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 7.95
HCP7328 OEM input/main axle shaft HALF-CIRCLE CLIP, fitted on the right end of the shaft on all XJ650, XJ700, XJ750, and XJ900RK engines. NOTE: all XJ650 (except Turbo) engines is shown as using only 1 of these clips, but we believe that is wrong, and just like all of the engines in these models, they should use 2 of these clips. All XJ650 Turbo, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines are specified to use 2 of these clips. Each:
$ 19.95
HCP7777 OEM input/main axle shaft CIRCLIP, fitted on the left end of the shaft, just inside the support bearing, on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 7.95
HCP10466 OEM main gear shaft BEARING HOUSING, use on all XJ650 Turbo, all XJ700 and XJ750-X models, and all XJ900RK, RL, N/FN, and F models. NOTE: this is the housing (cover) directly behind the shifter drum segment inside the shifter cover.
$ 42.95
- the following "wheel" gears and hardware components are located on the output drive axle shaft (or "counter-shaft"):
HCP7790 OEM output/counter-shaft 1st WHEEL GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 169.95
HCP12754 OEM output/counter-shaft 2nd WHEEL GEAR, for most 1980-81 XJ650 Maxim engines. NOTE: only fits 1980-81 XJ650 Maxim engines with engine case number 114697 or lower. and 1981 XJ650 Midnight Maxim models with engine case number 002134 or lower..
$ 199.95
HCP7804 OEM output/counter-shaft 2nd WHEEL GEAR, for all XJ650 and air-cooled XJ750 engines. NOTE: only fits 1981-later XJ650 engines with engine case number higher than 114697, or 1981 XJ650 Midnight Maxim models with engine case number higher than 002134.
$ 199.95
HCP7803 OEM output/counter-shaft 2nd WHEEL GEAR, for all XJ700, water-cooled XJ750-X, and all XJ900RK, RL, N/FN, and F engines. This gear will fit in place if HCP7804 above and is of a higher strength material.
$ 189.95
HCP7806 OEM output/counter-shaft 3rd WHEEL GEAR, for all 1980 and early 1981 XJ650 engines. NOTE: only fits 1981-later 650 engines with engine case number lower than 114697, or 650 Midnight Maxim models with engine case number lower than 002134.
$ 169.95
HCP7807 OEM output/counter-shaft 3rd WHEEL GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. NOTE: only fits 1981-later 650 engines with engine case number higher than 114697, or 650 Midnight Maxim models with engine case number higher than 002134.
$ 149.95
HCP7789 OEM output/counter-shaft 4th WHEEL GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 199.95
HCP7809 OEM output/counter-shaft 5th WHEEL GEAR, for all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. NOTE: only fits 1981-later 650 engines with engine case number higher than 114697, or 650 Midnight Maxim models with engine case number higher than 002134.
$ 199.95
HCP7814 OEM output/counter-shaft BEARING, left end, use on all XJ650 (except Turbo) and all XJ750 air-cooled engines.
$ 89.95
HCP7815 OEM output/counter-shaft BEARING, left end, use on all XJ650 Turbo, all XJ700, all water-cooled XJ750-X, and all XJ900RK, RL, N/FN, and F engines.
$ 39.95
HCP19259 Aftermarket output/counter-shaft BEARING, left end, use on all XJ650 Turbo, all XJ700, all water-cooled XJ750-X, and all XJ900RK, RL, N/FN, and F engines.
$ 29.95
HCP7813 OEM output/counter-shaft BEARING, right end, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 42.95
HCP19258 Aftermarket output/counter-shaft BEARING, right end, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 29.95
HCP7812 OEM output/counter-shaft SPACER WASHER, fitted between the 1st wheel and 4th wheel gears on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 6.95
HCP7322 OEM output/counter-shaft SPACER WASHER, fitted between the 2nd wheel gear and the 5th wheel gear on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 6.95
HCP7782 OEM output/counter-shaft SPACER WASHER, fitted between the 3rd wheel and 4th wheel gears on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 4.95
HCP7323 OEM output/counter-shaft CIRCLIP, fitted between the 2nd and 5th wheel gears on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 7.95
HCP7781 OEM output/counter-shaft CIRCLIP, fitted between the 3rd and 4th wheel gears on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 7.95
HCP8480 OEM main gear shaft bearing retainer housing RETAINING BOLT, use 3 per housing. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95
HCP2424 Aftermarket main gear shaft bearing retainer housing RETAINING BOLT, use 3 per housing. Black oxide coated alloy steel socket head, allen-drive. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 1.95
HCP80 Aftermarket main gear shaft bearing retainer housing RETAINING BOLT, use 3 per housing. Black oxide coated alloy steel socket head, allen-drive. Features a small nylon thread patch, making this a self-locking bolt. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95
HCP2423 Aftermarket main gear shaft bearing retainer housing RETAINING BOLT, use 3 per housing. Bright 18-8 stainless steel socket head, allen-drive. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 2.95
HCP10467 OEM main gear shaft bearing retainer housing O-RING, use 1 per housing. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 7.95
HCP22166 Aftermarket main gear shaft bearing retainer housing O-RING, use 1 per housing. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95
XJ650, XJ700, XJ750, and XJ900RK shifter forks:
HCP5055 OEM shifter forks SHAFT. For use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 44.95
HCP5056 OEM shifter forks shaft retaining CIRCLIP, for use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 6.95
HCP5052 OEM #1 SHIFTER FORK, for use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 99.95
HCP5053 OEM #2 SHIFTER FORK, for use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 99.95
HCP5054 OEM #3 SHIFTER FORK, for use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 99.95
XJ1100 and XS1100 engines:
- the following "pinion" gears and hardware components are located on the main axle shaft (or "input shaft"):
HCP7829 OEM input/main axle shaft BEARING, right end, use on all XJ1100 and XS1100 engines.
$ discontinued
HCP12778 OEM output/counter-shaft BEARING, left end, use on all XJ1100 and XS1100 engines.
$ discontinued
HCP7824 OEM input/main axle shaft 2nd/3rd PINION GEAR SET, for all XS1100 and XJ1100 engines.
$ 399.95
HCP7821 OEM input/main axle shaft 4th PINION GEAR SET, for all XS1100 and XJ1100 engines.
$ 219.95
HCP7827 OEM input/main axle shaft 5th PINION GEAR, for all XS1100 and XJ1100 engines.
$ 199.95
HCP7832 OEM input/main axle shaft SPACER WASHER, fitted at the far left end of the main axle shaft on all XS1100 and XJ1100 engines.
$ 7.95
HCP7822 OEM input/main axle shaft SPACER WASHER, fitted between the 2nd/3rd and the 4th pinion gears on all XS1100 and XJ1100 engines.
$ 29.95
HCP5060A OEM input/main axle shaft SPACER WASHER, fitted between the 2nd/3rd and the 5th pinion gears on all XS1100 and XJ1100 engines.
$ 7.95
HCP7828 OEM input/main axle shaft SPACER WASHER, fitted to the left of the 5th pinion gear on all XS1100 and XJ1100 engines.
$ 7.95
HCP7781 OEM input/main axle shaft CIRCLIP, fitted between the 2nd/3rd and 4th pinion gears on all XS1100 and XJ1100 engines.
$ 7.95
HCP7826 OEM input/main axle shaft CIRCLIP, fitted between the 2nd/3rd and 5th pinion gears on all XS1100 and XJ1100 engines.
$ 3.95
HCP7830 OEM input/main axle shaft CIRCLIP, fitted at the far right end of the main axle shaft on all XS1100 and XJ1100 engines.
$ 8.95
HCP7777 OEM input/main axle shaft CIRCLIP, fitted on the left end of the shaft, just inside the support bearing, on all XS1100 and XJ1100 engines.
$ 7.95
- the following "wheel" gears and hardware components are located on the output drive axle shaft (or "counter-shaft"):
HCP7848 OEM output/drive axle shaft BEARING, right end, use on all XJ1100 engines.
$ 49.95
HCP12778 OEM output/drive axle shaft BEARING, left end, use on all XJ1100 and XS1100 engines.
$ 59.95
HCP7834 OEM output/drive axle shaft 1st WHEEL GEAR, for all XS1100 and XJ1100 engines.
$ discontinued
HCP7840 OEM output/drive axle shaft 2nd WHEEL GEAR, for all XS1100 and XJ1100 engines.
$ discontinued
HCP7838 OEM output/drive axle shaft 4th WHEEL GEAR, for all XS1100 and XJ1100 engines.
$ discontinued
HCP7841 OEM output/drive axle shaft 5th WHEEL GEAR, for all XS1100 and XJ1100 engines.
$ discontinued
HCP7836 OEM output/drive axle shaft SPACER WASHER, fitted between the 1st and the 4th wheel gears on all XS1100 and XJ1100 engines.
$ 7.95
HCP7853 OEM output/drive axle shaft SPACER WASHER, fitted at the far right end of the output shaft on all 19801-81 XS1100 Specials and XJ1100 engines.
$ 7.95
HCP7837 OEM output/drive axle shaft CIRCLIP, fitted between the 1st and the 4th wheel gears, and between the 3rd and 4th wheel gears on all XS1100 and XJ1100 engines.
$ 7.95
HCP7846 OEM output/drive axle shaft CIRCLIP, fitted to the right of the middle drive gear on all XS1100 and XJ1100 engines.
$ 2.95
NOTE: in some situations, you can use the following technique to remove larger oil seals that would otherwise require case-splitting to remove. All large oil seals have a metal inner structure that you can (very carefully!) drill into and then pry out:
http://www.xjbikes.com/forums/threads/replacing-the-output-shaft-seal.110522
HCP7844 OEM output/drive axle shaft OIL SEAL, fitted at the far left side of the output shaft on all XJ1100 and XS1100 engines.
$ 39.95
HCP20945 Aftermarket output/drive axle shaft OIL SEAL, fitted at the far left side of the output shaft on all XJ1100 and XS1100 engines.
$ 29.95
XJ1100 shifter forks:
HCP5168 OEM #1 SHIFTER FORK, for use on all XS1100 and XJ1100 models.
$ discontinued
HCP5170 OEM #3 SHIFTER FORK, for use on all XS1100 and XJ1100 models.
$ discontinued
XJ650 - XJ1100 SHAFT DRIVE MIDDLE GEAR, U-JOINT, DRIVESHAFT, AND FINAL DRIVE PARTS:
Smooth and reliable, the Yamaha shaft-drive system is well designed and engineered to provide years of trouble-free service with minimal maintenance. Following the proper fluid-change schedules will result in miles of trouble-free operation. However, if the bike has been allowed to sit idle for an extended period of time, the various seals and o-rings will drive out and may develop leaks, which should be remedied as soon as possible......as oil leaks in the vicinity of the rear tire can lead to some awfully dreadful consequences.
As with other high-stress, high-heat mechanical area, your final drive system needs a top-quality lubricant and regular oil changes to maintain its performance and insure the longest life of the components. All shaft-drive XJ models should have their rear fluid changed every 5,000 miles (all XJ650, 1981-84 XJ750 except XJ750RL, and XJ1100 models) or every 16,000 miles (all XJ700, XJ750RL, and XJ900 models), and use SAE 80W or SAE 80W/90 Type GL-4 Hypoid Gear Oil. The final drive holds 0.2 liters of fluid (about 1/2 of a pint).
Middle Drive Gear and Driven Gear:
First of all, let's clear up a bit of terminology: what Yamaha refers to as the "middle gear" is actually inside the engine case (at the very rear of the engine case) on all XJ650- XJ900 engines, and in a separate housing on XJ1100 and XS1100 engines. It's in the "middle" of the entire power-transmission path (which loosely can be described as:
- the "forward" components being the engine and clutch/transmission components
- the "middle" being these "middle gear" components
- and the "rear" is the driveshaft and final drive components at the rear wheel.
Luckily, the MIDDLE GEAR COMPONENTS are practically bullet-proof, and rarely need any attention nor suffer significant enough wear to cause any problems. Usually, they outlast the bike itself.
Of course, there are exceptions to every rule, so here is a list of parts that are available, should the need ever arise.
And here’s some good videos showing the proper method of installing ball bearings into engine cases and onto shafts:
https://www.youtube.com/watch?v=5dThHN7Rj6c
and
https://www.youtube.com/watch?v=wXZ-agyDsXY
Transmission Middle DRIVE GEAR Components:
HCP7810 OEM transmission middle DRIVE GEAR, for all XJ650 (except Turbo), all XJ700, and all 1982 XJ750 Maxim and all 1983 XJ750 Midnight Maxim engines.
$ discontinued
HCP7811 OEM middle gear assembly DRIVE GEAR, for all XJ650 Turbo, all XJ750 Seca, 1983 XJ750 Maxim, all XJ900RK, RL, N/FN, and F engines.
$ 199.95
Transmission Middle DRIVEN Gear Components:
HCP7818 OEM middle gear assembly DRIVEN GEAR, for all XJ900RK, RL, N/FN, and F engines.
$ 189.95
HCP7788 OEM middle driven gear BEARING, right side of the middle driven gear, use on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 89.95
HCP7783 OEM middle driven gear BEARING, left side of the middle driven gear, use on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 59.95
HCP7849 OEM middle driven gear BEARING, use 1 on each side of the middle driven gear on all XJ1100 and XS1100 engines.
$ 79.95
HCP7854 OEM middle driven gear SPACER WASHER, fitted just to the left of the middle driven gear on all XJ1100 engines.
$ discontinued
HCP7786 OEM middle driven gear CIRCLIP, fitted to the right end of the middle drive gear on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines.
$ 5.95
HCP7787 OEM middle driven gear HALF-CIRCLE CLIP, fitted to the right end of the middle drive gear on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines. Use 1 per engine.
$ 10.95
HCP7784 OEM middle driven gear HALF-CIRCLE CLIP, fitted to the left end of the middle drive gear on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 engines. NOTE: use 1 of these clips on all of the above engines, and a total of three (3) of these half-circle clips on the XJ1100 models. Each:
$ 10.95
HCP20944 Aftermarket middle driven gear OIL SEAL, fits onto the output shaft where it exits the crankcase housing behind the bearing plate “half-moon” retainers. For all 1980-81 XJ650 Maxim and Midnight Maxim engines, 1982 XJ650RJ Seca, XJ650 Euro 4K0 models, and 1981-82 XJ750 Seca engines. Note that this seal is not used on any of the other engines in these model ranges.
$ 22.95
Middle Gear Input Gear Shaft:
The input shaft unit on the Middle Gear Assembly consists of a special spring-loaded damper unit and a heavy-duty shaft bearing.
HCP12851 OEM middle gear input shaft BEARING, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 89.95
HCP12852 OEM middle gear input shaft SPECIAL NUT, fits all XJ650 and 181-83 XJ750 engines.
$ 14.95
HCP12853 OEM middle gear input shaft DRIVE CAM, fits all XJ650 (except Turbo) and 1981-83 XJ750 engines.
$ 64.95
HCP12869 OEM middle gear input shaft DRIVE CAM, fits all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F engines.
$ 54.95
HCP12870 OEM middle gear input shaft DRIVEN CAM, fits all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F engines.
$ 59.95
HCP12871 OEM middle gear input shaft SPRING, fits all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F engines.
$ 21.95
HCP12856 OEM middle gear input shaft SPRING HOLDER, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ discontinued
HCP12857 OEM middle gear input shaft THRUST WASHER, use 2 per shaft on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. Each:
$ 8.95
HCP28405 OEM middle gear input shaft THRUST SHIM .15mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ discontinued
HCP12858 OEM middle gear input shaft THRUST SHIM .20mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 7.95
HCP12859 OEM middle gear input shaft THRUST SHIM .30mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 19.95
HCP12860 OEM middle gear input shaft THRUST SHIM, .40mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 19.95
HCP28406 OEM middle gear input shaft THRUST SHIM, .50mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ discontinued
HCP10469 OEM middle gear input shaft bearing RETAINER PLATE, half-moon shaped plate used on the upper crankcase section. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, F, and S/SH models.
$ 27.95
HCP10472 OEM middle gear input shaft bearing RETAINER PLATE, half-moon shaped plate used on the lower crankcase section. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, F, and S/SH models.
$ 12.95
HCP10470 OEM middle gear input shaft bearing retainer plates TORX SCREW, use 2 with each of the half-moon shaped plate retainer plates. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, F, and S/SH models. Each:
$ 7.95
HCP22176 Aftermarket middle gear input shaft bearing retainer plates TORX SCREW, use 2 with each of the half-moon shaped plate retainer plates. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, F, and S/SH models. Each:
$ 3.95
HCP12868 OEM middle gear input shaft gear-to-shaft retainer TABBED LOCK WASHER, use 1 on all XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each
$ 3.95
Middle Gear Output Shaft:
HCP12862 OEM middle gear output shaft BEARING, use on all XJ650, XJ700, and all XJ900RK, RL, N/FN, and F models. NOTE: this is the bearing on the front (or forward) end of the output shaft. The rear output shaft bearing is part of the output housing and is not available as a separate component.
$ 39.95
HCP19278 Aftermarket middle gear output shaft BEARING, use on all XJ650, XJ700, and all XJ900RK, RL, N/FN, and F models. NOTE: this is the bearing on the front (or forward) end of the output shaft. The rear output shaft bearing is part of the output housing and is not available as a separate component.
$ 29.95
HCP12861 OEM middle gear output shaft forward bearing retaining HALF-CIRCLE CLIP, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 5.95
Note that the following pinion shims are “half-circle”; thus 2 shims of each size (thickness) are required to be fitted to make one “shim” spacing on the shaft/gear. Shim sizes can be calculated through a procedure outlined in the factory service manual, and the stock shim sizes (for your particular engine) are scrawled into the upper crankcase (along with the crank main journal sizes) as can be seen here, in the sectioned titled “Crankcase Main Bearing Sizes”:
http://www.xj4ever.com/catalog/frame-engine-id.pdf
HCP28409 OEM middle gear output shaft PINION GEAR SHIM .10mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 24.95
HCP13745 OEM middle gear output shaft PINION GEAR SHIM .15mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 15.95
HCP13747 OEM middle gear output shaft PINION GEAR SHIM .20mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 15.95
HCP13748 OEM middle gear output shaft PINION GEAR SHIM .30mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 15.95
HCP13749 OEM middle gear output shaft PINION GEAR SHIM .40mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 15.95
HCP13750 OEM middle gear output shaft PINION GEAR SHIM .50mm thick, use on all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines, as well as the following non-XJ models: . 1982-83 XZ550 K/RK/RJ Vision, 1987-88, 1990, and 1993 and 1995-00 XV535 Virago, and 1998-16 XVS650 V-Star models. Each:
$ 15.95
Middle Gear Output Shaft Housing (except XJ1100 and XS1100 models:
HCP12863 OEM middle gear output shaft HOUSING, fits all XJ650 and 1981-83 XJ750 engines.
$ 119.95
HCP12867 OEM middle gear output shaft HOUSING, fits all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F models.
$ 104.95
HCP12864 OEM middle gear output shaft housing BOLT, fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines. Use 4 per housing. Each:
$ 1.50
HCP7260 OEM middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 13.95
HCP21656 Aftermarket middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 9.95
NOTE: in some situations, you can use the following technique to remove larger oil seals that would otherwise require case-splitting to remove. All large oil seals have a metal inner structure that you can (very carefully!) drill into and then pry out:
https://www.xjbikes.com/forums/threads/replacing-the-output-shaft-seal.110522
HCP6080 OEM middle gear output housing OIL SEAL, fits on the output shaft “X”-flange where it exits the crankcase housing. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 23.95
HCP20943 Aftermarket middle gear output housing OIL SEAL, fits on the output shaft “X”-flange where it exits the crankcase housing. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 18.95
HCP10471 OEM middle gear cavity-to-shifter case cavity rubber GROMMET, fits into the recess on the crankcase on the southwest corner of the middle gear cavity (northeast corner of the shifter cover cavity) in the crankcase. For all XJ650, all XJ700 engines, all XJ750 engines, and all XJ900RK, RL, N/FN, F, and S/SH engines.
$ discontinued
HCP21657 Aftermarket middle gear cavity-to-shifter case cavity rubber GROMMET, fits into the recess on the crankcase on the southwest corner of the middle gear cavity (northeast corner of the shifter cover cavity) in the crankcase. For all XJ650, all XJ700 engines, all XJ750 engines, and all XJ900RK, RL, N/FN, F, and S/SH engines.
$ 19.95
Middle Gear Output Flange, Seals, and Hardware:
Even though the output flange rarely gets damaged, the seals can leak and should be replaced if such a situation develops, and these items can be replaced without splitting the engine cases apart.
HCP6082 OEM middle gear output shaft to u-joint FLANGE, the cast "X" flange that the U-Joint bolts to. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models.
$ 49.95
HCP6083 OEM middle gear output shaft flange O-RING, fits under the flange nut and washer. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 5.95
HCP20655 Aftermarket middle gear output shaft flange O-RING, fits under the flange nut and washer. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 3.95
HCP6084 OEM middle gear output shaft flange PLATE WASHER. Fits all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 7.95
HCP6085 OEM middle gear output shaft flange NUT, retains the flange to the middle gear output shaft. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 16.95
HCP2239 OEM middle gear output shaft flange NUT, retains the flange to the middle gear output shaft. Fits all XJ1100 and XS1100 models.
$ 11.95
HCP7260 OEM middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 13.95
HCP21656 Aftermarket middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 9.95
Middle Gear Housing (XJ1100 and XS1100 models):
XJ1100 and XS1100 models were unique in that the middle gear components were housing separate from the crankcase, inside their own little gear case. Listed below are the most common items that may need replacement.
HCP7248 OEM middle gear input shaft BEARING, right end, used on all XJ1100 and XS1100 engines.
$ 34.95
HCP12290 OEM middle gear input shaft BEARING, left end, used on all XJ1100 and XS1100 engines.
$ 122.95
HCP7261 OEM middle gear output shaft BEARING, forward end, used on all XJ1100 and XS1100 engines.
$ 39.95
HCP7262 OEM middle gear output shaft BEARING, rear end, used on all XJ1100 and XS1100 engines.
$ 44.95
HCP7272 OEM middle gear housing-to-crankcase GASKET for all XJ1100 and XS1100 models.
$ 29.95
HCP22412 Aftermarket middle gear housing-to-crankcase GASKET for all XJ1100 and XS1100 models.
$ 19.95
HCP7257 OEM middle gear housing outer cap GASKET for all XJ1100 and XS1100 models.
$ discontinued
HCP22411 Aftermarket middle gear housing outer cap GASKET for all XJ1100 and XS1100 models.
$ 21.95
HCP7245 OEM middle gear housing input shaft housing O-RING, fits where the input shaft cover joins the main case. For all XJ1100 and XS1100 models.
$ 7.95
HCP22007 Aftermarket middle gear housing input shaft housing O-RING, fits where the input shaft cover joins the main case. For all XJ1100 and XS1100 models.
$ 5.95
HCP967 OEM middle gear housing-to-crankcase locating DOWEL PIN, use 1 per engine on all XJ1100 and XS1100 models. Each:
$ 4.95
HCP7260 OEM middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 13.95
HCP21656 Aftermarket middle gear output housing O-RING, fits on the inside of the output shaft housing. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F engines, and XJ1100 and XS1100 models.
$ 9.95
NOTE: in some situations, you can use the following technique to remove larger oil seals that would otherwise require case-splitting to remove. All large oil seals have a metal inner structure that you can (very carefully!) drill into and then pry out:
https://www.xjbikes.com/forums/threads/replacing-the-output-shaft-seal.110522
HCP6081 OEM middle gear output housing OIL SEAL, fits on the output shaft where it exits the crankcase housing. For all XJ1100 and XS1100 models.
$ 24.95
HCP7273 OEM middle gear housing BOLT, use 1 per engine. This is the short housing bolt in the upper rear position of the housing. Class 10.9 alloy steel sockethead cap screw with a bright finish. For the following models: XJ1100. Each:
$ 4.95
HCP29771 Aftermarket middle gear housing BOLT, use 1 per engine. This is the short housing bolt in the upper rear position of the housing. Alloy steel sockethead cap screw with a black oxide finish. For the following models: XJ1100. Each:
$ 1.95
HCP29772 Aftermarket middle gear housing BOLT, use 1 per engine. This is the short housing bolt in the upper rear position of the housing. Alloy steel sockethead cap screw with a bright zinc-flake finish. For the following models: XJ1100. Each:
$ 2.95
HCP29773 Aftermarket middle gear housing BOLT, use 1 per engine. This is the short housing bolt in the upper rear position of the housing. 18/8 stainless steel sockethead cap screw with a bright finish. For the following models: XJ1100. Each:
$ 2.95
HCP29774 Aftermarket middle gear housing BOLT, use 1 per engine. This is the short housing bolt in the upper rear position of the housing. 316 stainless steel sockethead cap screw with a bright finish. For the following models: XJ1100. Each:
$ 3.95
Swingarm-to-Engine Case Rubber Boot:
ctd2) Located where the swingarm tunnel joins the engine case, this accordion style rubber boot keeps all the nasty stuff out. Tears in this boot will allow grit and moisture in and cause expensive problems down the road. These boots are retained with a large tension spring which should also be replaced when the boot is serviced.
NOTE: it is a good idea to puncture a small (meaning a pencil- point sized) drain hole in these boots in the bottom edge, near the front, in-between the first two folds, to allow any water that may naturally accumulate within the boot to drain.
HCP488 OEM driveshaft RUBBER BOOT, pleated accordion rubber boot fits all XJ650, XJ750, and all XJ900RK, RL, N/FN, and F models. Retention spring HCP489 must be ordered separately below. Each:
$ discontinued
HCP2220 OEM driveshaft RUBBER BOOT, pleated accordion rubber boot fits all XJ1100 and XS1100 models. Retention springs HCP489 (front) and HCP4196 (rear) must be ordered separately below. Each:
$ 69.95
HCP489 OEM driveshaft boot RETENTION SPRING, round tension spring retains the front of the rubber boot on all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and XS1100 models. Each:
$ 12.95
HCP4196 OEM driveshaft boot RETENTION SPRING, round tension spring retains the rear of the rubber boot on all XJ1100 and XS11000 models. Each:
$ 16.95
Cross-Joint:
sdp2) Original or rebuilt "U-Joint" or CROSS-JOINT perfectly replace worn or damaged original piece. The U-joint takes quite a beating during its life----and should be replaced if damage, wear, or excessive play is noticed. The last thing you want to have happen to you, when you're tooling down the freeway, is to have this cross joint fail!
Driveshaft Cross-joint Evaluation:
Is this you?:
"Everybody should go check their u-joints before you have my problem. I admit I like going fast, and doing hard starts. And it caught up with me.............my u-joint was within a few miles of complete self-destruction before I caught it, and the removed u-joint is scary. So if you've got over 50,000 miles on your bike, then this is critical!"
Here's how to check your driveshaft u-joint:
a) Put the bike on the centerstand, and put in 5th gear. Rotate the back tire back-and-forth. There should be minimal slack. If there is more than 1/2" of rotation, you may have a serious problem
b) Pull the swingarm boot on the shaft back as far as possible, and use a flashlight or a finger to probe for metal peelings on the arms of the joint. If you can feel shards or what feels like bent metal, replace the u-joint ASAP!
c) If you feel a vibration that shakes the whole bike, pull over and get the bike towed home. It's worth doing that, rather than ending up with a destroyed crankshaft, u-joint, driveshaft, or worse!
https://www.xjbikes.com/forums/threads/driveshaft-noise-vibration.129568
NOTE: in reference to the rebuilt cross-joints listed below, the word "un-damaged" means that the driveshaft mating splines are not damaged, the cross-joint does not show evidence of physical damage to the casting itself, and that the threaded flange mounting holes are not stripped out.
HCP6088 OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ650 and 1981-84 XJ750 models, brand new.
$ discontinued
HCP6088RB OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ650 and 1981-84 XJ750 models, rebuilt with new u-joint. A refundable core-charge of $ 79.00 will be charged (in addition to the part price below) with the purchase of this part, and will be refunded to you upon the return of your original, un-damaged cross-joint.
$ 199.95 + $ 79.00 refundable core charge
HCP6087 OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F models, brand new.
$ discontinued
HCP6087RB OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F models, rebuilt with new u-joint. A refundable core-charge of $ 79.00 will be charged (in addition to the part price below) with the purchase of this part, and will be refunded to you upon the return of your original, un-damaged cross-joint.
$ 199.95 + $ 79.00 refundable core charge
HCP6086 OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ1100, XS850, and XS1100 models, brand new..
$ discontinued
HCP6086RB OEM shaft-drive CROSS-JOINT (commonly referred to as a U-Joint), for all XJ1100, XS850, and XS1100 models, rebuilt with new u-joint. A refundable core-charge of $ 79.00 will be charged (in addition to the part price below) with the purchase of this part, and will be refunded to you upon the return of your original, un-damaged cross-joint.
$ 199.95 + $ 79.00 refundable core charge
HCP3793 OEM middle gear output flange-to-cross joint BOLT. Use 4 per joint. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F, XJ1100, and XS1100 models. Each:
$ 7.95
Driveshaft:
sdp7) Original manufacturer DRIVESHAFT perfectly replace worn or damaged original pieces. Although the driveshaft itself rarely wears out, its rear oil seal takes quite a beating during operation----and becomes a potential source of annoying oil leaks. Always lubricate the driveshaft splines with high-temp grease when installing.
NOTE: Although all of the XJ-series driveshafts look the same, there are differences in the shaft size (OD of the shaft itself) and the overall length of the shaft. 1980-81 XJ650 Maxim and Midnight Maxim use a smaller OD shaft, while the 1982-84 XJ650 and 1981-83 XJ750 models share the same (larger OD) driveshaft. XJ700, XJ750-X, and XJ900 models have a bigger, beefier, and longer driveshaft than the others, and the XJ1100 models use a unique style driveshaft used only on that model.
A good write-up on the removal process can be viewed at:
http://www.xjbikes.com/forums/threads/driveshaft-removal-question.112460/
and this following guide is also useful, even though it is for the XS750/850 models:
https://www.yamahatriples.com/how_tos/final-drive-overhaul
HCP6859 OEM shaft-drive DRIVESHAFT, for all XJ700, XJ750-X, and all XJ900RK, RL, N/FN, and F models.
$ 119.95
HCP12302 OEM driveshaft front retaining C-CLIP. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. This is the c-clip located behind the u-joint. NOTE: some 1980-82 XJ650 and XJ750 models used a retaining wire (not a c-clip) at the front of the driveshaft, which serves to lock the driveshaft into the u-joint. This c-clip is not that wire clip, and the wire clip is not currently available.
$ 7.95
HCP5108 OEM driveshaft REAR OIL SEAL, fits at the rear of the driveshaft, and seals where the shaft gear enters into the final drive input coupler gear. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F. Each:
$ 25.95
HCP20948 Aftermarket driveshaft REAR OIL SEAL, fits at the rear of the driveshaft, and seals where the shaft gear enters into the final drive input coupler gear. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F. Each:
$ 21.95
HCP12300 OEM driveshaft rear oil seal FLAT WASHER. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 7.95
HCP12301 OEM driveshaft rear oil seal washer retaining C-CLIP. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 6.95
HCP5114 OEM driveshaft REAR OIL SEAL, fits at the rear of the driveshaft, and seals where the shaft gear couples to the final drive input coupler gear. For all XJ1100 and XS1100 models. Each:
$ 39.95
HCP20950 Aftermarket driveshaft REAR OIL SEAL, fits at the rear of the driveshaft, and seals where the shaft gear couples to the final drive input coupler gear. For all XJ1100 and XS1100 models. Each:
$ 24.95
HCP12299 OEM driveshaft REAR TENSION SPRING, fits at the rear of the driveshaft, and mates to the final drive input coupler gear. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F, and XJ1100 models.
$ 6.95
Final Drive Input Parts and Seals:
ctd12) The final drive input shaft accepts the rear gear of the driveshaft via a coupler within the front "snout" of the final drive housing.......and it's a potential source of annoying oil leaks. New rubber OIL SEALS and input shaft COUPLERS, BEARINGS, and HARDWARE allows you to rebuild these critical components properly; however, be aware the special tools and gauges may be needed to properly dis-assemble the input and output shafts for bearing and oil seal replacement. NOTE: be aware that the input shaft gear coupler retaining nut is a reverse-thread design; it unscrews by turning clockwise.
A good write-up on what’s involved in servicing a leaking final drive unit can be reviewed at::
http://www.xjbikes.com/forums/threads/driveshaft-removal-question.112460
and this following guide is also useful, even though it is for the XS750/850 models:
https://www.yamahatriples.com/how_tos/final-drive-overhaul
HCP11676 OEM final drive housing-to-swingarm STUD, used to attach the input snout on the final drive housing to the rear of the driveshaft tube on the swingarm. Use 4 per housing. Fits all 1982-83 XJ650 models, all XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 9.95
HCP2230 OEM final drive housing-to-swingarm stud LOCK WASHER, use 1 per bolt, for all 1980 XJ650 Maxim, all XJ700, and all XJ750-X models. Each:
$ 7.95
HCP22225 Aftermarket final drive housing-to-swingarm stud LOCK WASHER, zinc-plated alloy steel. Use 1 per bolt, for all 1980 XJ650 Maxim, all XJ700, and all XJ750-X models. Each:
$ 2.95
HCP22227 Aftermarket final drive housing-to-swingarm stud LOCK WASHER, 18/8 stainless steel. Use 1 per bolt, for all 1980 XJ650 Maxim, all XJ700, and all XJ750-X models. Each:
$ 3.95
HCP3497 OEM final drive housing-to-swingarm stud LOCK WASHER, use 1 per bolt, for all 1981-83 XJ650 Maxim, all XJ750 non-X, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 7.95
HCP22226 Aftermarket final drive housing-to-swingarm stud LOCK WASHER, black finish. Use 1 per bolt, for all 1981-83 XJ650 Maxim, all XJ750 non-X, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 2.95
HCP6154 OEM final drive housing-to-swingarm stud LOCKING NUT, use 1 per bolt, for all 1980 XJ650 Maxim models. Each:
$ 2.95
HCP11678 OEM final drive housing-to-swingarm stud NUT, use 1 per bolt, for all 1981-83 XJ650 Maxim, all XJ750 non-X, all XJ900RK, RL, N/FN, and F models. Each:
$ 8.95
HCP4661 OEM final drive housing-to-swingarm stud CROWN NUT, semi-polished bright finish, use 1 per bolt, for all XJ700 and XJ750-X models. Each:
$ 8.95
HCP16424 Aftermarket final drive housing-to-swingarm stud CROWN NUT, high-polished chrome-plated finish, use 1 per bolt, for all XJ700 and XJ750-X models. This nut is a bit taller (and lacks the flanged base) compared to the original HCP4661 nut, and has a beautiful, highly polished chrome finish compared to the stock OEM nut, and the extra height is visually pleasing. Each:
$ 9.95
HCP12298 OEM final drive housing input GEAR COUPLER, fits at the front of the final drive input housing and accepts the splined end of the driveshaft. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 99.95
HCP6083 OEM middle gear output shaft flange O-RING, fits under the flange nut and washer. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 9.95
HCP20655 Aftermarket middle gear output shaft flange O-RING, fits under the flange nut and washer. Fits all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F engines.
$ 6.95
HCP12296 OEM final drive housing input gear coupler RETAINING WASHER. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95
HCP2239 OEM final drive housing input gear coupler RETAINING NUT. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 11.95
HCP5109 OEM final drive housing INPUT OIL SEAL, fits at the front of the final drive input housing, behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 17.95
HCP20949 Aftermarket final drive housing INPUT OIL SEAL, fits at the front of the final drive input housing, behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 13.95
HCP6188 OEM final drive housing INPUT O-RING, fits at the front of the final drive input housing, behind the driveshaft gear coupler. For all XJ1100 and XS1100 models. Each:
$ 9.95
HCP12290 OEM final drive housing input shaft front BEARING, located behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. Each:
$ 122.95
HCP509 OEM final drive housing input shaft front BEARING, located behind the driveshaft gear coupler. For all XS850, 1979 XS1100 Standard, and 1980-81 XS1100 all models. Each:
$ 49.95
HCP12293 OEM final drive housing input shaft front bearing RETAINER HOUSING, located behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 59.95
HCP12294 OEM final drive housing front bearing retainer O-RING, fits on the retainer housing behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 9.95
HCP7523 OEM final drive housing input shaft front bearing THRUST SHIM, 0.15mm thick. For all XJ650, XJ700, XJ750, and all HCP7523 OEM final drive housing input shaft front bearing THRUST SHIM, 0.15mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ discontinued
HCP7524 OEM final drive housing input shaft front bearing THRUST SHIM, 0.30mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95
HCP7525 OEM final drive housing input shaft front bearing THRUST SHIM, 0.40mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95
HCP7526 OEM final drive housing input shaft front bearing THRUST SHIM, 0.50mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 5.95
HCP12287 OEM final drive housing input shaft front bearing THRUST SHIM, 0.60mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ discontinued
HCP12289 OEM final drive housing input shaft bearing EXPANSION SPACER, fits in-between the front and middle bearings. For all XJ1100 models. Each:
$ 35.95
HCP12288 OEM final drive housing input shaft middle BEARING. For all XJ1100 models. Each:
$ discontinued
HCP12279 OEM final drive housing input shaft rear ROLLER BEARING, located behind the driveshaft gear coupler. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and all XS1100 models. This bearing uses a separate race which is not included with the bearing. Each:
$ 42.95
HCP12278 OEM final drive housing input shaft rear roller bearing RACE, used with the HCP12279 bearing above. Each:
$ 34.95
Final Drive Output Parts and Seals:
ctd22) The final drive output gears delivers the power output to the rear wheel. New rubber OIL SEALS, BEARINGS, and HARDWARE allows you to rebuild this assembly correctly; however, be aware the special tools and gauges are needed to properly dis-assemble the input and output shafts for bearing and oil seal replacement.
HCP9348 OEM final drive housing OUTPUT OIL SEAL, fits on the output bearing housing. This is the very large oil seal that IS visible when you are looking at the final drive housing when it is removed from the wheel. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and XS1100 models. Each:
$ 29.95
HCP9765 OEM final drive housing OUTPUT O-RING, fits on the inside of the output bearing housing. This is the very large o-ring that is NOT visible when you are looking at the final drive housing when it is removed from the wheel. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and XS1100 models. Each:
$ 16.95
HCP5107 OEM final drive housing OUTPUT OIL SEAL, fits on the pinion gear shaft. This is the small oil seal that is NOT visible when you are looking at the final drive housing when it is removed from the wheel. Must be serviced using special procedures and the HCP9209 driver tools. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and XS1100 models. Each:
$ 17.95
HCP20951 Aftermarket final drive housing OUTPUT OIL SEAL, fits on the pinion gear shaft. This is the small oil seal that is NOT visible when you are looking at the final drive housing when it is removed from the wheel. Must be serviced using special procedures and the HCP9209 driver tools. For all XJ650, XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, XJ1100, and XS1100 models. Each:
$ 14.95
HCP12320 OEM final drive output GUIDE COLLAR, inside the final drive housing. Must be serviced using special procedures and the HCP9209 driver tools. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 27.95
HCP12322 OEM final drive output BEARING HOUSING. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 54.95
HCP8407 OEM final drive output bearing housing mounting BOLT. For all XJ650, XJ700, and XJ750 models. Use 2 per housing. Each:
$ 8.95
HCP12319 OEM final drive output bearing housing mounting STUD. For all 1980-81 XJ650 Maxim and Midnight Maxim models. Use 6 per housing. Each:
$ 18.95
HCP12321 OEM final drive output bearing housing mounting STUD. For all 1982-3 XJ650 Maxim models, all XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 6 per housing. Each:
$ 6.95
HCP12326 OEM final drive output bearing housing mounting stud WAVE WASHER. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 6 per housing. Each:
$ 6.95
HCP3494 OEM final drive output bearing housing mounting stud NUT. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 6 per housing. Each:
$ 3.95
HCP24037 Aftermarket final drive output bearing housing mounting stud NUT, made from 18/8 stainless steel. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Use 6 per housing. Each:
$ 2.95
HCP12323 OEM final drive output BEARING, within the final drive housing. Must be serviced using special procedures and the HCP9209 driver tools. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 59.95
HCP12324 OEM final drive output BEARING, wheel side of the ring gear. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 134.95
HCP12327 OEM final drive housing output ring gear SHIM, 0.25mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 11.95
HCP12328 OEM final drive housing output ring gear SHIM, 0.30mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 11.95
HCP12329 OEM final drive housing output ring gear SHIM, 0.35mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 21.95
HCP12330 OEM final drive housing output ring gear SHIM, 0.40mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 11.95
HCP12331 OEM final drive housing output ring gear SHIM, 0.45mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 22.95
HCP12332 OEM final drive housing output ring gear SHIM, 0.50mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 11.95
HCP12333 OEM final drive housing output ring gear THRUST WASHER, 1.40mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP12334 OEM final drive housing output ring gear THRUST WASHER, 1.50mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP12336 OEM final drive housing output ring gear THRUST WASHER, 1.70mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP12340 OEM final drive housing output ring gear THRUST WASHER, 2.00mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP12341 OEM final drive housing output ring gear THRUST WASHER, 2.10mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP12342 OEM final drive housing output ring gear THRUST WASHER, 2.20mm thick. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N and FN models. Each:
$ 29.95
HCP13770 OEM final drive housing output ring gear THRUST WASHER, 1.20mm thick. For all XJ900F models. Each:
$ 14.95
HCP13771 OEM final drive housing output ring gear THRUST WASHER, 1.40mm thick. For all XJ900F models. Each:
$ 11.95
HCP13772 OEM final drive housing output ring gear THRUST WASHER, 1.60mm thick. For all XJ900F models. Each:
$ 11.95
HCP13773 OEM final drive housing output ring gear THRUST WASHER, 1.80mm thick. For all XJ900F models. Each:
$ 11.95
HCP13774 OEM final drive housing output ring gear THRUST WASHER, 2.00mm thick. For all XJ900F models. Each:
$ discontinued
HCP12325 OEM final drive output/wheel clutch hub SPACER TUBE this almost 3” long tube spacer fits on the wheel side of the final drive housing, into the splined clutch hub on the left side of the wheel. If this spacer is missing, you will not be able to align the rear wheel properly side-to-side within the swingarm. For all XJ650, XJ700, XJ750, and all XJ900RK, RL, N/FN, and F models. Each:
$ 21.95
Final Drive Breather Valve:
At the very top center of your shaft-drive rear wheel housing, there is what looks like a grey plastic cap----which many people mistake for the oil filler plug. This cap is really part of the housing oil BREATHER VALVE, and luckily, it almost never needs replacing unless it somehow gets damaged. If it does, replacement valves are available below. Note that these valve "press-fit" into the final drive housing.
HCP6228 OEM final drive housing BREATHER VALVE, for all XJ650 models except Midnight Maxims and 1983 XJ650 Turbo, all XJ700 models, all XJ750 models except Midnight Maxims, and all XJ900RK, RL, N/FN, and F models.
$ 24.95
HCP6227 OEM final drive housing BREATHER VALVE, for all XJ650 Midnight Maxim, 1983 XJ650 Turbo, XJ750 Midnight Maxim, and XJ1100 models.
$ 49.95
Final Drive Filler and Drain Port Plugs:
PLEASE!: always use anti-seize compound on the threads when installing any of these bolts!
NOTE and commentary: We highly recommend the use of the magnetic style drain plugs in both the crankcase oil pan and the final drive drain holes. It's an added measure of safety to trap metallic particles and keep them from circulating suspended in the oil.
The various magnetic drain plugs listed below have the following characteristics that should be considered when deciding on which one to purchase:
HCP1656 aftermarket plug---has the strongest magnetic pull of them all, but has the smallest hex head size of the bunch (14mm). Use anti-seize on the threads before installing, and do not over-torque it (31 ft-lbs is the factory spec for use as an engine oil drain plug, and 16 ft-lb as a final drive drain) and this should not be a problem.
HCP1472 oem magnetic plug----magnetic pull is "okay", but not anywhere as strong as the HCP1656 plug above. However, this drain plug does have a 9mm extended "probe" or tip which is the magnetized part, and thus it would extended further into the oil flow than any of the other drain plugs listed. This plug has a large 17mm hex head.
HCP1654 aftermarket plug---very weak magnetic pull. Has a 19mm head.
HCP23863 aftermarket plug---magnetic pull is "okay", but not anywhere as strong as the HCP1656 plug above. Has a 19mm head.
HCP1477 oem non-magnetic plug---obviously, no magnetic pull at all. On the plus side, it has the large 17mm head, and it's the least expensive of the bunch.
HCP1477 OEM final drive OIL FILLER PLUG, with a 17mm hex head. This plug is NOT magnetic. Crush washer HCP1475 or HCP17987 must be ordered separate. Fits all XJ650, all XJ700, XJ750, all XJ900RK, RL, N/FN, and F models final drive FILLER port. NOTE: the head on this bolt is smaller than the original final drive drain plug, which had a 19mm hex head.
$ 11.95
HCP6161 OEM final drive OIL FILLER PLUG, with a flat 19mm diameter head, 6mm hex-drive. Crush washer HCP1475 or HCP17987 must be ordered separate. Fits: all XJ1100 final drive FILLER port.
$ 18.95
HCP4962 OEM final drive oil filler plug DECORATIVE BLACK CAP, this push-in black plastic cap (“cover”) fits into the socket head of the HCP6161 bolt, and makes for a nice pretty finished appearance. Each:
$ 7.95
HCP26235 Aftermarket final drive oil filler plug DECORATIVE BLACK CAP, this push-in black plastic cap (“cover”) fits into the socket head of the HCP6161 bolt, and makes for a nice pretty finished appearance. Each:
$ 5.95
HCP1472 OEM final drive MAGNETIC OIL DRAIN PLUG, with a 17mm hex head. This plug has a central, removable "binding screw" through the center of the head (used for installation of a temperature probe at the dealership). The 9mm extended magnetic probe tip helps catch metal particles in the oil. Crush washer HCP1475 or HCP17987 must be ordered separate. Although I have no way of measuring the magnetic field, it appears that the magnetic pull of this drain plug is quite a bit weaker than of the HCP1656 aftermarket magnetic drain plug listed below. Fits all XJ650, all XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models final drive DRAIN port. NOTE: the head on this bolt is smaller than the original final drive drain plug, which had a 19mm hex head.
$ 39.95
HCP6186 OEM middle gear and final drive OIL DRAIN PLUG, with a 17mm hex head. This plug IS magnetic. Crush washer HCP1475 must be ordered separate . Fits all XJ1100 models for the middle gear and final drive DRAIN ports.
$ 19.95
HCP1654 Aftermarket final drive MAGNETIC OIL DRAIN PLUG, with a large 19mm hex head. It comes with the crush washer. Bright cad-plated. It is very weakly magnetic. Fits all XJ650, all XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models final drive DRAIN port. Can also be used as a final drive FILLER plug.
$ 24.95
HCP1656 Aftermarket final drive MAGNETIC OIL DRAIN PLUG, with a small 14mm hex head. It comes with the crush washer. Although I have no way of measuring the absolute magnetic strength of any of these plugs, the magnetic pull of this drain plug is quite a bit stronger than either the HCP1472, HCP1654, or HCP23863 magnetic drain plugs. Fits all XJ650, all XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models final drive DRAIN port. Can also be used as a final drive FILLER plug.
$ 19.95
HCP23863 Aftermarket fluid port MAGNETIC OIL FILLER OR DRAIN PLUG, with a large 19mm hex head. It comes with the crush washer. Although I have no way of measuring the absolute magnetic strength of any of these bolts, the magnetic pull of this drain plug is about the same as either the HCP1472 or HCP1654 magnetic drain plugs. Fits all XJ650, all XJ700, XJ750, all XJ900RK, RL, N/FN, and F models, and XJ1100 models final drive DRAIN port. Can also be used as a final drive FILLER plug.
$ 17.95
dp3) OEM final drive filler or drain plug CRUSH WASHER----these should be replaced every time you change your fluid.
HCP1475 OEM oil pan drain, final drive filler, and final drive drain bolt CRUSH WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, 1984-91 XJ600 Euro, 1992-98 XJ600 Seca II, all XJ650, XJ700, XJ750, all XJ900, XJ1100, and XS1100 models; is also is used for XJ1100 and XS1100 middle gear drain bolt. Each:
$ 3.95
$ 18.95 pack of 5
HCP17987 Aftermarket oil pan drain, final drive filler, and final drive drain bolt CRUSH WASHER, fits all XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, 1984-91 XJ600 Euro, 1992-98 XJ600 Seca II, all XJ650, XJ700, XJ750, all XJ900, XJ1100, and XS1100 models; is also is used for XJ1100 and XS1100 middle gear drain bolt. Each:
$ 2.95
$ 12.95 pack of 5
DRIVELINE TOOLS:
Driveline Service 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.
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.
$ 99.95
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.
$ 139.95
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.
$ 49.95
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.
$ 89.95
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.
$ 119.95
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.
$ 189.95
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.
$ 169.95
Super-Penetrant Fluids and Lubricants:
Sometimes, the toughest part of working on a vehicle is battling the effects of time: seized fasteners, caused by rust, corrosion, and other factors, turns what should be a 5-minute effort into a 50-minute (or more) chore, complete with rounded-off, ruined, or snapped fasteners, e-z outs, heli-coil inserts, and more.........and that's just not right.
While the proper use of our various Anti-Seize products will prevent these nightmares from occurring in the future, you're stuck in the here-and-now, and the best way to handle these obstacles is to have the proper tools at the stand-by; and in the case of fastener seizure, the proper "tool" is a can or two of our SUPER PENETRATING LUBRICANTS at the ready; a couple of squirts, a little bit of time-----perhaps some heat for those really nasty situations----and you're on your way again, hopefully not too much worse for the experience.....
Great for use on all fasteners, fork tube cap bolts, intake and exhaust manifolds bolts, studs, and nuts, lock cylinder tumblers, or anywhere an un-cooperative fastener can be found. Can even be used to help un-seize frozen engines!
Be aware that these products are not your typical, garden-variety, run-of-the-mill "retail" type products; these are designed an used as industrial- and military-strength products, meaning they have special formulations that include a dollop more of the "good stuff" within them to solve the toughest seizure problems imaginable (the "good stuff" ingredients cost more, and it is those compounds that are left out of or reduced in concentration in "retail" level consumer products).
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.
HCP10331 Aftermarket standard-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Oil-based lubricant penetrates down into spaces of one-millionth of an inch to handle the most reluctant seizures. Actually dissolves the rust and corrosion that causes the seizure; lubricates and displaces moisture to prevent rust re-formation. This product is what we use and recommend for freeing stuck fork tube cap bolts and other such challenging fasteners.
$ 44.95
HCP11974 Aftermarket super-duty PENETRATING LUBRICANT, in a generous 13-ounce aerosol can. Same as our standard-duty formula above, but also includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. The cat's-meow of penetrating fluids, can even be used to un-seize frozen engines or as an engine assembly lube! This fluid is also a great choice for use as a drive cable lubricant.
$ 46.95
HCP10333 Aftermarket extreme-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Same as our standard-duty formula above, but also includes liquid silicone to enhance and speed up the penetrant action. This product is also an exceptional choice for use as a control-cable lubricant.
$ 47.95
Assembly Fluids and Lubricants:
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.
HCP20860 Aftermarket industrial-strength ASSEMBLY LUBE, in a standard 12-ounce aerosol can. Heavy-duty formula includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. Won't wash away, protect against rust and corrosion, stable from 0-degrees up to 250-F. This fluid is also a great choice for use as a drive cable lubricant.
$ 41.95
HCP20862 Aftermarket super-duty ASSEMBLY LUBE, in a generous 10-ounce aerosol can. The cat's-meow of lubricants, infused with pure moly disulfide, it goes on wet and then dries in 1-2 hours to a super-slick, high-pressure, hi-temp, bearing-like finish which provides the ultimate level of protection. Prevents rust and corrosion, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can even be used as an engine, tranny, and drivetrain assembly lube!
$ 44.95
HCP20863 Aftermarket super-duty GRAPHITE LUBE, in a generous 10-ounce aerosol can. The 800-pound gorilla of lubricants, it's infused with pure graphite, goes on wet, and then dries in 10 minutes to a super-slick, high-pressure, bearing-like finish which provides the ultimate level of protection. Prevents rust, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can be used as an engine assembly lube, bearing or bushing pre-lube, great for lock cylinders, and all metallic sliding surfaces. Use where dusty or dirty conditions render oil-based lubricants ineffective or undesirable.
$ 42.95
Final Drive Gear Oil:
As with other high-stress, high-heat mechanical area, your final drive system needs a top-quality lubricant and regular oil changes to maintain its performance and insure the longest life of the components. All shaft-drive XJ models should have their rear fluid changed every 5,000 miles (all XJ650, 1981-84 XJ750 except XJ750RL, and XJ1100 models) or every 16,000 miles (all XJ700, XJ750RL, and XJ900 models), and use SAE 80W or SAE 80W/90 Type GL-4 Hypoid Gear Oil. The final drive holds 0.2 liters of fluid (about 1/2 of a pint).
Our PETROLEUM-BASED GEAR OIL easily meets all original specifications, is an excellent value, and comes in a 1 quart container, enough for 2 oil changes.
Our "SHOCK-PROOF" SYNTHETIC GEAR OIL is the finest product you can purchase for the use in your final drive system and far exceeds the OEM specifications. Sold in a 1 quart container, enough for 2 oil changes.
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.
HCP10374 Aftermarket petroleum-based 85-90W FINAL DRIVE GEAR OIL, 1 quart bottle.
$ 27.95
HCP9844 Aftermarket synthetic "shock-proof" 80W FINAL DRIVE GEAR OIL, 1 quart bottle.
$ 39.95
Gear Assembly Grease:
gm2) Aftermarket high-temp, high-performance SYNTHETIC GREASES coat, lubricate, insulate, and protect metal bearings, bushings, gears, and other metal-to-metal contact points. Waterproof, high-temp (-40F to + 450F) white synthetic grease is silica thickened and contains a healthy dose of PTFE for friction reduction. Red-moly synthetic greases are also great for wheel bearings, steering neck bearings, swingarm bearings, starter motor gears and the like.
HCP8574 Aftermarket tube of white PTFE-enhanced SYNTHETIC GREASE, half-ounce tube.
$ 9.95
HCP8575 Aftermarket tube of PTFE-enhanced SYNTHETIC GREASE, 3-ounce tube. Same as HCP8574 above, just in a larger size.
$ 14.95
HCP8608 Aftermarket gear and bearing synthetic RED MOLY SYNTHETIC GREASE. High temperature, water resistant, extreme pressure and high-load strength synthetic organic moly grease is far superior to black moly disulfide (petroleum-based) products. Use on steering neck bearings, wheel bearings, starter motor gears, and swingarm bearings. 14 oz. tube.
$ 29.95
HCP9783 Aftermarket engine assembly WHITE LITHIUM GREASE. High temperature, water resistant, extreme pressure and high-load strength lithium grease is preferred for engine assembly lubrication on bearings, piston rings, gears, and other moving parts. Protects critical parts until the oil gets flowing. 6 oz. squeeze tube is enough to do one engine. Great for middle and final drive gearsets, too.
$ 11.95
Anti-Seize Paste:
xx1) Fastener ANTI-SEIZE PASTE. Yeah, it's smelly and makes a slippery mess on your fingers, but this stuff is a life-saver for any true wrencher, because it prevents problems down the road. Use it on any metal fastener that does not require a "loctite" thread-locker material to be used. This means on just about every fastener that is carb, engine case, or suspension-related! (except for carb upper and lower rack-mount screws and butterfly valve screws, which do require the use of a thread-lock fluid). If you think that it might, sometime, in the future, need to come off: use anti-seize compound! NOTE: the "base" metal material used in the different anti-seize pastes below do not determine what type of fastener to use such pastes on; it merely signifies what base material is used to create the anti-seize paste. You can use any "base-metal" anti-seize paste on any type of fastener and metal.
NOTE: the use of anti-seize compounds will result in a TORQUE-MULTIPLYING EFFECT……..the result of a reduction in friction between the threaded contact points……and thus fasteners treated with anti-seize compound should have their torque values reduced by at least 10-15% when installed into steel material, and up to 25% into aluminum materials or other “soft” metals” (such as spark plugs into cylinder heads, or almost any other type of fastener into the engine) …… note that this rule applies only to service manual torque specifications on fasteners that are not indicated to be treated with anti-seize fluid by the factory …. if the factory manual specifies the use of an anti-seize coating, then the specified torque value for that fitting already takes into account the “reduced torque” necessary.
http://raskcycle.com/techtip/webdoc14.html
http://www.cncexpo.com/MetricBoltTorqueNm.aspx
http://www.bmwmotorcycletech.info/sparkplugs.htm
http://www.antiseize.com/pdf/torque_specifications.pdf
HCP1264 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based in a 1-ounce squeeze tube, for smaller jobs.
$ 8.95
HCP29921 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based in a 4-gram pillow pack, for individual jobs (enough for a single carb rack, or front-end rebuild, brake system rebuild, etc.)
$ 3.95
HCP1265 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based formula in a 4-ounce tub with a brush-lid, for larger jobs.
$ 11.95
HCP9784 Aftermarket fastener ANTI-SEIZE PASTE, standard grade aluminum-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 17.95
HCP9763 Aftermarket fastener ANTI-SEIZE PASTE, standard-grade copper-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 17.95
HCP9764 Aftermarket fastener ANTI-SEIZE PASTE, premium-grade nickel-based formula in an 8-ounce tub with a brush-lid, a lifetime supply for your motorcycle!
$ 24.95