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SECTION P:
THE TOOLBOX, LOWER DRAWERS:
ENGINE 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.
Oil Pressure Gauge:
The part that Yamaha forgot. In almost all high-performance engine settings, the measurement and knowledge of operating oil pressure is a vital part of operator information. These following kits allow you to monitor the engine oil pressure on a periodic or continuous basis, allowing you to monitor critical internal engine conditions.
NOTE: 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.
These engine OIL PRESSURE MEASURING KITS contains everything you’ll need to take periodic measurements of the engine oil pressure………something that Yamaha never provided a means to do, for some unknown reason(s). Periodically measuring the oil pressure in the your engine can provide clues as to the health of various engine components (not just the oil pump condition, but more importantly, bearing clearances….as excessive bearing clearances will “leak” pressurized oil and reduce oil pressure, thus leading to all sorts of problems). Thus keep track of oil pressures over time is an important “maintenance” procedure, akin to checking cylinder compression pressure periodically.
This kit contain a specially made main oil gallery plug and a liquid-filled mini oil pressure gauge. The gallery plug replaces the left side factory gallery plug ----- the one directly below the left crankshaft end cover (which was actually called an “oil pump cover" by Yamaha, for some odd reason……). Once installed, you can run the engine and check oil pressures at various engine temps, and record the readings. Although you can leave the gauge installed permanently, we do not recommend this, as it does stick out past the pump cover and you risk damage of epic proportions if anything were to disturb it…….
Each kit comes with block-off plug, so that the gauge assembly can be removed while leaving the gallery plug in place; then, the block-off plug replaces the gauge assembly and creates a leak-proof solution, while leaving the gallery plug in place, ready to re-use (re-installation of the gauge) whenever is necessary.
And although Yamaha does not specify oil pressures for their engines, they do note that the oil pump relief valve is set to open at 64-78 psi, so you can use that as a guide.
HCP28415 Aftermarket engine OIL PRESSURE MEASURING KIT contains everything you’ll need to take periodic measurements of the engine oil pressure. Fits all XJ650 - XJ900 engines. Each:
$ 99.95
HCP28418 Aftermarket engine OIL PRESSURE MEASURING KIT contains everything you’ll need to take periodic measurements of the engine oil pressure. Fits all XS1100 engines. Each:
$ 99.95
HCP28678 Aftermarket engine OIL PRESSURE MEASURING KIT contains everything you’ll need to take periodic measurements of the engine oil pressure. Fits all XJ1100 engines. Each:
$ 99.95
Cylinder Compression Gauge:
Yamaha recommends that you perform a compression test every 5,000 miles or so, and that you should record the readings, per cylinder, for future comparison and evaluation. The acceptable readings (specified at sea level) are as follows:
To do a compression test properly, you should first make sure all of your engine valves are properly adjusted to their recommended clearances, as valves that are too "tight" (not enough clearance) will allow the intake or exhaust valve to be open more than is necessary, or at the wrong time within the compression stroke cycle, thus bleeding off compression that would otherwise be developed.
http://www.xjbikes.com/forums/threads/compression-test-xj650.113151
Do not use thread adapters or the like on your pressure gauge, as the added volume of air space within the adapter will reduce the indicated pressure readings.
a) make sure the engine is warm (at operating temperature).
b) remove all spark plugs, and then stick the plugs back into their caps and make sure the plugs are grounded to the cylinder head (or even better, disconnect your TCI unit).
c) remove the airbox filter lid and the air filter.
d) make sure the battery is FULLY charged, and remains so throughout the course of these tests! It is actually recommended that for purposes of compression testing that the TCI be un-plugged and jumper cables to a large capacity battery (i.e. car battery) be used to make sure that the cranking speed remains pretty constant between each reading. Slow or sluggish cranking speeds will reduce the indicated compression pressure. Yamaha specifies their compression pressures at 300 rpms (which is why the battery needs to be in good shape).
e) open the throttle FULLY and keep it open during testing.
f) crank the engine over until the needle stops advancing.
g) Let the starter cool down for a minute or so, then do the next cylinder, etc..
h) If the readings are below spec, then shoot about a teaspoon of motor oil into each cylinder, turn the engine over a few revolutions by hand or with the starter (to spread the oil around), and then re-test each cylinder using the above procedure.
i) compare the two results and analyze.
j) keep all of your figures, and note the date and mileage from your odometer, so you can compare the next time you take readings (every 5,000 miles or so).
The specified compression pressures should be:
XJ550 engines:
Minimum: 100 psi
Standard: 121 psi
Maximum: 135 psi
Max. variance between lowest and highest: 14 psi
FJ600 engines:
Minimum: 142 psi
Standard: 156 psi
Maximum: 164 psi
Max. variance between lowest and highest: 14 psi
XJ600 Seca II engines:
Minimum: 145 psi
Standard: 160 psi
Maximum: 167 psi
Max. variance between lowest and highest: 14 psi
XJ650 and XJ750 air-cooled engines:
Minimum: 128 psi
Standard: 156 psi
Maximum: 171 psi
Max. variance between lowest and highest: 14 psi
XJ700 non-X (air-cooled) engines:
Minimum: 128 psi
Standard: 156 psi
Maximum: 171 psi
Max. variance between lowest and highest: 14 psi
XJ700-X and XJ750-X (water cooled) engines:
Minimum: 154 psi
Standard: 159 psi
Maximum: 165 psi
Max range allowable between highest and lowest readings: 14 psi
XJ900 engines:
Minimum: 114 psi
Standard: 142 psi
Maximum: 171 psi
Max. variance between lowest and highest: 14 psi
XJ1100 engines:
Minimum: 128 psi
Standard: 142 psi
Maximum: 156 psi
Max. variance between lowest and highest: 14 psi
NOTE: for readings taken at locations that are above sea level (ASL), the following correction factors should be applied to the readings that your gauge obtains:
- 500' ASL, multiply your readings by 1.013 to get a "true" compression reading.
- 1000' ASL, multiply your readings by 1.029 to get a "true" compression reading.
- 1500' ASL, multiply your readings by 1.042 to get a "true" compression reading.
- 2000' ASL, multiply your readings by 1.060 to get a "true" compression reading.
- 2500' ASL, multiply your readings by 1.072 to get a "true" compression reading.
- 3000' ASL, multiply your readings by 1.093 to get a "true" compression reading.
- 3500' ASL, multiply your readings by 1.103 to get a "true" compression reading.
- 4000' ASL, multiply your readings by 1.126 to get a "true" compression reading.
- 4500' ASL, multiply your readings by 1.136 to get a "true" compression reading.
- 5000' ASL, multiply your readings by 1.160 to get a "true" compression reading.
- 5500' ASL, multiply your readings by 1.172 to get a "true" compression reading.
- 6000' ASL, multiply your readings by 1.196 to get a "true" compression reading.
- 7000' ASL, multiply your readings by 1.233 to get a "true" compression reading.
- 8000' ASL, multiply your readings by 1.272 to get a "true" compression reading.
Also, be aware that barometric pressure differences (during testing events separated by more than just a few hours) will cause changes in indicated compression readings. Atmospheric pressure can vary significantly over time at the same altitude, due to weather systems….you hear this on weather reports, where the forecaster is talking about “High” and “Low” pressure systems. Basically, higher atmospheric pressures translate into higher indicated compression pressures. Although it is rarely of major consequence, in order to be "dead-nuts" accurate you should also record your local barometric pressure at the time of each test. If you measured compression on a day when it was 1030mbar and observed 150psi, and then took a measurement later in the week/month/etc. when the ambient air pressure was only 990mbar, that’s an environmental air pressure difference of about 4%, and assuming nothing else had changed you would then read a 4% less compression pressure of only 144psi......i.e. lower ambient air pressure results in lower compression pressures in your engine.
But don’t overlook the fact that the individual test gauge being used is probably the greatest variable. Some compression gauges are just not very accurate to begin with (basically, and within reason --- and just like with most tools --- the more it costs, the more accurate it will tend to be). Also, try to keep the hose on the gauge you are using as short as possible….the space inside the hose adds to the volume of the cylinder, as lowers the compression ratio a bit, and thus reduces compression pressures.
And in case you are interested, here are the standard compression ratios for the various engines:
XJ550: 9.5-to-1
FJ600: 10.0-to-1
XJ600 Seca II: 10.0-to-1
XJ650 (except Turbo): 9.2-to-1
XJ650 Turbo: 8.2-to-1
XJ700 air-cooled: 9.5-t-1
XJ700-X and XJ750-X water: 11.2-to-1
XJ750 air: 9.2-to-1
XJ900: 9.6-to-1
XJ1100: 9.0-to-1
XS1100 9.2-to-1
Note that the XJ650 Turbo engine has a much lower static CR than all other engines……logically so, since it has a device (the turbocharger!) that raises the atmospheric pressure of the incoming air charge. Also of note is the rather “sky-high” CR of the multi-valve Genesis engines in the water-cooled “X” engines, which is also one of the keys to their vastly increased power output.
Now Analyze This!:
1) If one or all of your cylinders are too low in pressure, it means that:
a) you did the compression test incorrectly
b) the tester gauge is inaccurate, or was not used properly.
c) your engine has piston ring, piston wall, or valve leakage problems.
d) you valve clearances are too tight, and should be adjusted, or the cams are out of time, or aftermarket camshafts have been fitted that have altered the camshaft timing.
e) if a cylinder or cylinders have NO compression at all, that typically means your piston has been catastrophically damaged (i.e. a hole in the piston crown, broken piston, etc.)
f) if a cylinder or cylinders have good compression that rapidly "leaks away" (best determined by the use of a Leakdown Tester gauge as listed further below), this points to burned or otherwise problematic valves.
In order to further analyze a low-compression condition, you should squirt a small amount of engine oil into the suspect cylinders (about a teaspoon), crank the engine over for a few revolutions to spread the oil about, and then re-test those cylinders. NOTE: if cranking the engine over with the starter motor, you should place a rag or similar over the spark plug opening, or the oil you just introduced into the cylinder may spray out forcefully (into your face, onto your engine, all over the place……….!).
g) if the compression pressures RISE by a large amount after the infusion of oil, then this typically means that the pistons, piston rings, or cylinder walls are damaged or worn in some way(s). However, be aware that if you introduced a significant amount of oil into a cylinder (1 teaspoon or more) when conducting this test, a small rise in pressure may occur, and it may instead mean that your valves are the problem, since the introduction of that much oil in a small cylinder will naturally cause the compression to rise.
h) if the compression pressures do NOT rise after the infusion of oil, then this typically means that the valve seats or faces are worn, or a valve is hanging up within its guide, or your valve clearances are way too small (thus keeping a valve open all the time throughout the entire compression stroke).
i) if two adjacent cylinders (cylinders 1 and 2, or cylinders 3 and 4) have low compression, and the oil treatment produces no greater pressures, this points to a damaged cylinder head gasket, warped head, etc.
j) it can be very useful to introduce 20-30 psi of compressed air into the cylinder (thru the spark plug hole) to help identify the source of low compression: the escaping air can pinpoint the source of the leak (air hissing out of the intakes or exhaust points to valve problems, while air escaping thru the crankcase breather indicates ring-seal issues).
Of course, many other situation may cause low cylinder compression, including valves that are out of adjustment (too tight, thus holding a valve slightly open all the time, losing compression), cracked pistons, cylinders, or cylinder heads, but those situations are the not all that common.
2) If one or all of your cylinders are too HIGH in pressure, it means that:
a) you piston domes (tops) and/or the cylinder head combustion chamber have a significant accumulation of carbon upon them, which should be cleaned via some type of chemical treatment or engine dis-assembly and manual removal methods. Note that higher cylinder pressures caused by such build-up may be "masking" or hiding other problems that might cause LOW cylinder pressures, such as worn rings, etc.
b) your engine has been fitted with aftermarket, high-compression pistons, or has had the cylinder head mating surface significantly "shaved".
NOTE: high cylinder pressures are NOT a good thing, as they tend to blow out head gaskets and can cause accelerated piston, piston ring, or bearing wear.
You can also test for piston ring and cylinder wall condition by performing a "leak-down" test, which consists of forcing a measured amount of compressed air into a cylinder, and then seeing how long before this air "leaks" out of the combustion chamber and down into the crankcase (past the ring seal):
http://www.dietersmotorsports.com/Compression-leakdowntest.htm
NOTE: be aware that some of the ultra low-priced gauges that are typically advertised on eBay, etc. can be quite un-reliable in their readings, and may regularly indicate a false (low) compression reading.
HCP16268 Aftermarket BASIC COMPRESSION TESTER KIT. This dial-type compression pressure gauge contains everything you'll need to check the "health" of those four holes: a 2-1/2" diameter, 0-300 psi gauge with an integrated pressure release valve, a separate 12" long flex hose, and a 10mm, 12mm, 14mm, and 18mm plug adapters. Soft storage pouch, instructions, and a compliment of replacement o-rings and core valves are included. This is a good basic kit.
$ 59.95
HCP16269 Aftermarket PROFESSIONAL COMPRESSION TESTER KIT......this versatile, affordably-priced, accurate set contains everything you'll need to check the "health" of those four holes: a 2-3/4" gauge head---calibrated in psi, kPa, kg/cm2, and bar scales---with an integral pressure-relieved valve, permanently attached to a 10" hose with a quick-release coupler. A complete variety of 10mm, 12mm, 14mm, and 18mm adapter fittings and extensions hoses allows for maximum flexibility and ease of use on all types of engines. Comes in a handy plastic storage case, with a user guide, and a field service kit.
$ 89.95
Cylinder Leakdown Gauge:
In addition to a compression test gauge, another important means of determining the condition of the pistons/rings/cylinders is via a PRESSURE LEAKDOWN TESTER GAUGE. The standard compression tests can read maximum compression achieved, and that is all well and good; but equally important is whether that maximum compression pressure can be held by the rings and valves. A special "pressurize and hold" leakdown tester is necessary to perform this type of testing, and is great device to have when diagnosing the true condition of an engine's top end.
HCP17850 Aftermarket PROFESSIONAL PRESSURE LEAKDOWN TESTER KIT......this versatile, affordably-priced, accurate set contains everything you'll need to check the "health" of those four holes: gauge head, regulator valve, permanently and a set of extension hoses with 10mm, 12mm, and 14mm fittings for use on all types of 4-stroke engines. Comes in a handy plastic storage case with a user guide. NOTE: requires the use of an air compressor for use.
$ 159.95
Valvetrain Tools:
dd2) Aftermarket camshaft chain BREAKER AND RIVETER TOOLS, needed to properly break and rivet a master link onto the replacement cam chains listed above. NOTE: these tools are quite expensive to purchase for one-time use (especially the riveter tools). You may be able to find a local shop that rents the proper tools for a much more affordable price than purchasing one.
HCP8607 Aftermarket cam chain BREAKER AND RIVETER TOOL.
$ 129.95
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 2mm TIP for HCP9203 tool kit.
$ 9.95
HCP9205 Aftermarket 3mm TIP for HCP9203 tool kit.
$ 9.95
HCP9206 Aftermarket 4mm TIP for HCP9203 tool kit.
$ 9.95
HCP9207 Aftermarket WEDGE RIVETING TIP for HCP9203 tool kit.
$ 9.95
HCP26935 Aftermarket TDC FINDER tool, for all models with 14mm spark plug threads. To properly align your cams after removal, it is necessary to be able to precisely locate Top Dead Center (TDC) of the # cylinder, and it’s not always possible or advisable to rely on the timing pointer. This simple “sliding rod” TDC finder tool is easy to use, very precise, and affordable. Each:
$ 9.95
Valve Cover Pressure Washer Installation Tool:
HCP17542 Aftermarket valve cover pressure washer INSTALLATION TOOL........a lifesaver little device to make quick and easy work of installing the HCP1621, HCP1622, HCP19931 pressure washers into their bolts, and useful (but not absolutely necessary) on the HCP1620 pressure washers. This tapered brass collar is the proper size to allow the pressure washer to easily slide over its retaining flange or "ring" on bolt, eliminating the grinding ordeal of trying to press or wedge the new washer over that flange (it ain't easy!). See it in action here: https://www.xjbikes.com/forums/thre...-tool-now-with-how-to-pics.40308/#post-351301
$ 1.95
Valve Shim Bucket Retaining Tool:
These reproductions of the original shim BUCKET RETAINER TOOL are required when removing or installing valve shims on air-cooled engines. NOTE: these tools are NOT needed to check the valve shim clearance, it is only necessary if you have determined that a shim needs to be changed and you are going to extract the current in-place shim from its bucket.
However, we recommend that you purchase the tool before you even begin the entire valve-clearance checking process, as chances are almost 100% that some - most - all of your valve clearances are out of spec, and to determine which replacement shims you'll need, you'll need to have this tool available to extract the currently installed shims (to check their size, and thus make the determination of what replacement sizes you'll need).
If you "measure clearances" and find that they are out of spec, and only then wait to order this tool, you'll be throwing your efforts behind by a week or so, and you'll be doing twice the amount of work. For the relatively small price of the tool, which you will need (whether now or in the future), it's our recommendation that you have it "at the ready" whenever you go thru the clearance-checking procedure, so you don't have to 2- or 3-step the process.
HCP247A Aftermarket valve shim BUCKET RETAINER TOOL. For use with all 1982-83 XS400, XJ500, 1982-83 ZX550, XJ550, 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, XJ650, XJ700 air-cooled, XJ750 air-cooled, 1977-79 XS750, 1980-81 XS850, all XJ900RK, RL, N/FN, and F engines, XJ1100, and XS1100 engines. Each:
$ 19.95
Please note that although this tool is patterned off the original Yamaha tool, and will work properly, although it can be somewhat "tricky" to figure out the procedure the first time you use it:
http://xjbikes.com/forums/index.php?threads/29209
and
HCP22099 Aftermarket valve shim BUCKET RETAINER TOOL. For use with all XJ600 Seca II engines.
$ 22.95
HCP28363 Aftermarket valve shim BUCKET RETAINER TOOL. For use with all 1985-07 VMX1200 V-Max, 1983-85 XVZ1200 Venture Royale, and 1983-93 XVZ1300 Venture/Venture Royale engines.
$ 94.95
Valve Shim Feeler Gauge Sets:
v7) Aftermarket valve clearance FEELER GAUGES SETS. These dual offset-blade design with their 90-degree angled ends makes it easy to check the valve clearance on all XJ air-cooled motors. XJ700-X and XJ750-X (water-cooled) engines will require the use of much narrower feeler gauges to check the intake valve clearances on those models.
HCP1593 Aftermarket valve clearance FEELER GAUGES SET, combined .002"/.003" blades.
$ 7.95
HCP1594 Aftermarket valve clearance FEELER GAUGES SET, combined .004"/.005" blades.
$ 7.95
HCP1595 Aftermarket valve clearance FEELER GAUGES SET, combined .006"/.008" blades.
$ 7.95
HCP159345SET---set of all three gauges, 1 each of HCP1593, HCP1594, and HCP1595 gives you all of the most common sizes needed.
$ 22.95
We also carry traditional multi-blade feeler gauge sets. Which one should you order? Well, it depends on whether you like your readings to be based in standard-size DECIMAL or [/b]METRIC[/b] readings (both gauges have the corresponding sizes in their opposite equivalents, but the "round number" readings vary between the two sets). Since these are metric bikes, and the valve shim clearance charts and the shims are denominated in metric, we tend to prefer the metric gauges:
HCP6383 Aftermarket METRIC FEELER GAUGES SET. These gauges will work on all XJ engines including the XJ700-X and XJ750-X water-cooled models, which require narrower blade-tip feeler gauges to check the intake valve clearances on those models. Aftermarket 32-blade metric set has 95mm long blades, hardened and polished, with the thin, tapered ends needed to access the valves on these models. Marked in both metric and decimal equivalents, as listed below. NOTE: these feeler gauges will fit perfectly, although you will have to rotate the blade 90 degrees to the holder for some of the inner valves on X-models. Each:
$ 17.95
Comment: the inclusion of inch measurements AND the inclusion of smaller sizes makes this set ideal for all XJ-bikes and especially for X-models.
X-engines have valve clearances in a range from .004" - .012" (0.11 mm - .30 mm)
Metric (millimeter) sizes:
.03, .04, .05, .06, .07, .08, .09, .10, .13, .15, .18, .20, .23, .25, .28, .30, .33, .38, .40, .45, .50, .55, .60, .63, .65, .70, .75, .80, .85, .90, and 1.00mm
Decimal (inch) Sizes:
.001, .0015, .002, .0025, .0028, .003, .0035, .004, .005, .006, .007, .008, .009, .010, .011, .012, .013, .015, .016, .018, .020, .022, .024, .025, .026, .028, .030, .032, .034, .035, and .040.
HCP3445 Aftermarket DECIMAL FEELER GAUGES SET. These gauges will work on all XJ engines EXCEPT XJ700-X and XJ750-X models, which require thinner feeler gauges to check the intake valves clearances on those models. Complete set of 3-1/4" long straight-blade feeler gauges combines all sizes from .0015" thru .035" (each blade is also marked in its metric equivalents, from .038mm thru .889mm) on a handy storage ring. Sizes on the blades are listed in both decimal and metric dimensions. Includes a 2-1/2" long ruler. Each:
$ 16.95
Non-"X" engines have valve clearances in a range from .004" - .008" (0.11 mm - .20 mm)
Metric (millimeter) sizes:
.0381, .0508, .0635, .0762, .1016, .1270, .1524, .1778, .2032, .2286, .2540 (steel and brass), .2794, .3048, .3302, .3556, .3810, .4064, .4318, .4572, .4826, .5080, .5334, .5588, .5842, .6096, .6350, .6604, .7112, .7620, .8128, and .8890
Decimal (inch) Sizes:
.0015, .002, .0025, .003, .004, .005, .006, .007, .008, .009, .010, 0.011, .012, .013, .014, .015, .016, .017, .018, .019, .020, .021, .022, .023, .024, .025, .026, .028, .030, .032, and .035
Valve Clearance Crankshaft Nut Wrench:
To rotate the engine during valve clearance checks, you'll need the use of a proper sized open-end wrench to engage the special flat-sided nut on the left end of the crankshaft. A box end wrench or socket is not going to work. This is an odd-sized and difficult-to-locate wrench at most hardware or big-box stores.
HCP9640 Aftermarket OPEN-END WRENCH, 6" forged steel "engineer's wrench" has only one opening, and smooth black finish. Fits all XJ engines.
$ 18.95
Valve Face and Seat Reconditioning:
Typically known “lapping”, this is the most effective means of touching up slightly burned valves and seats, to restore like-new performance at minimum expense, and should be done whenever the head is off for service. And even after a valve grinding, a light lapping may be desirable. Modern valve refacing and reseating methods bring sealing surfaces into nearly full contact. However, slight irregularities, caused by vibration of equipment over a long period, make a lapping step the best way to be certain of a perfect job.
The proper spinning-while-grinding action, and the periodic lifting of the valve off the seat, is necessary to allow the abrasive compound to reposition itself uniformly on the valve and seat. After a final cleaning of compound from the valve, we recommend a few turns with oil to lift the remaining compound from the pores of the metal and to allow more accurate clearance adjustments. A well-seated valve, guided centrally and given proper clearance, is almost certain to give long service.
Our valve lapping tools, compounds, and complete kit makes this process easy (well, okay, a little bit “easier”) and will allow you to achieve a professional result.
HCP23549 Aftermarket valve lapping ABRASIVE PASTE, high quality grease-based 120-grit lapping paste is good for the initial lapping of valves that have a quite a bit of wear. Comes in a 2-ounce tub, more than enough to do an entire head.
$ 7.95
HCP23551 Aftermarket valve lapping ABRASIVE PASTE, high quality grease-based 180-grit lapping paste is good for the initial lapping of valves that are in good shape, and as a second step if using the 120-grit paste first. Comes in a 2-ounce tub, more than enough to do an entire head.
$ 7.95
HCP23555 Aftermarket valve lapping ABRASIVE PASTE, high quality grease-based 240-grit lapping paste is used to further smooth the surfaces after the use of the 180-grit compound. Comes in a 2-ounce tub, more than enough to do an entire head.
$ 7.95
HCP23559 Aftermarket valve lapping ABRASIVE PASTE, high quality grease-based 320-grit lapping paste is used to further smooth the surfaces after the use of the 240-grit compound. Comes in a 2-ounce tub, more than enough to do an entire head.
$ 7.95
HCP23561 Aftermarket valve lapping ABRASIVE PASTE, high quality grease-based 400-grit lapping paste is used final polishing to get a beautifully finished valve face and head seat. Comes in a 2-ounce tub, more than enough to do an entire head.
$ 7.95
HCP23571 Aftermarket lapping paste APPLICATOR BRUSH, high quality 6” brush allows you to carefully grab and spread small amounts of the paste.
$ 2.95
HCP25245 Aftermarket high-spot machinist MARKING PASTE, better known as “Prussian Blue”, this non-drying formula is used to find any high spots on the valve/seat interface, showing whether further lapping is necessary. Comes in a 3/4-ounce squeeze tub, cleans up with mineral spirits, and is more than enough to do an entire head.
$ 6.95
HCP23541 Aftermarket valve holder LAPPING STICK, specially-shaped wooden stick with a rubber “suction-cup” on one end that holds the valve securely while performing the back-and-forth lapping action. Pushbutton vacuum-suction system allows the valve to be held firmly, flexes without popping off, spins easily in your hands, and lifts the valve without losing its grip. Comes with 3 different sizes of suction cups to ensure proper fitting to the valve pad. A very nice tool.
$ 59.95
HCP23573 Aftermarket VALVE LAPPING KIT, contains everything you’ll need to do a preofessional job:
the HCP23541 lapping stick, one tub of each of the 120, 180, 240, 320, and 400 grit compounds, the applicator brush, a tube of the marking paste, and a set of usage instruction.
$ 89.95
Valve Spring Compressors:
Necessary to properly remove and install valve into the head, these special OEM tools allow you to do this job properly, without distorting or damaging the springs.
HCP9215 OEM valve SPRING COMPRESSOR TOOL, comes with adapters to allow the use on all XJ550, XJ650, and XJ750 engines.
$ 189.95
HCP9240 OEM valve SPRING COMPRESSOR TOOL, comes with adapters to allow the use on all XJ700, XJ900RK, and XJ1100 engines. XJ700-X and XJ750-X owners will also need to order the HCP9241 adapter below.
$ 189.95
HCP9241 OEM valve SPRING COMPRESSOR TOOL ADAPTER, for use with the HCP9240 compressor tool listed above, on the XJ700-X and XJ750-X engines.
$ 79.95
HCP10181 Aftermarket VALVE SPRING COMPRESSOR TOOL SET, comes with 5 different size adapters to allow use on all XJ-series engines, including the Maxim-X type multi-valve engines. NOTE: although this screw-type compressor tool comes with five different-sized retainer disc "adapters", you may find that none of the specific adapter sizes fits your valve spring retainers "perfectly". However, you merely need to select the size adapter that most closely fits the retainer size on your engine (never bigger, always smaller than the O.D. of the retainer disc) and use that adapter carefully (so it does not "slip" or "walk off" the edge of the retainer disc as you are applying pressure, as you DO NOT under any circumstances want it to "walk-over" the edge of the retainer and then scar the lifter bucket bore!).
Although the OEM sized adapters fit the retainer discs "perfectly" (and therefore do not pose this "walking and potential scarring of the lifter bucket bore" threat), the huge difference in price between the OEM tools listed above and this complete, high-quality compressor tool set makes it worthy of purchasing, as long as you are careful in its use. Our experience shows that the 30mm adapter will fit the retainer discs very well (or exactly on some models) on the 550-1100 engines (except the 700-X and 750-X water-cooled models). The "X" motors will use the 19mm adapter; but it will not fit the retainer perfectly, but is the closest practical size.
Comes in a handy plastic storage case.
$ 59.95
Valve Guide Tools:
vgt1) Aftermarket valve guide tools are necessary to properly install replacement valve guides into the cylinder head. These reproductions of the original Yamaha specialty tools allow you to do the job properly.
HCP9234 Aftermarket valve guide REMOVAL AND INSTALLATION DRIVER TOOL, properly sized to remove original pressed-in valve guides without damaging the head, as well as to drive the guide installation tool HCP9232 used to install new guides. For all XJ550 engines.
$ 39.95
HCP9232 Aftermarket valve guide INSTALLATION TOOL, necessary to properly install the shoulderless valve guides into the head. Use this tool along with the driver tool HCP9234. For all XJ550 engines.
$ 39.95
HCP9231 Aftermarket valve guide REAMER TOOL. When new valve guides are installed, they should be reamed to a proper size and finish to allow the specified valve-to-guide clearance and insure proper lubrication, but no oil suction through the guides. For all XJ550 engines.
$ 129.95
HCP9216 Aftermarket valve guide REMOVAL AND INSTALLATION DRIVER TOOL, properly sized to remove original pressed-in valve guides without damaging the head, as well as to drive the guide installation tool HCP9217 used to install new guides. For all XJ650, XJ700 non-X, XJ750, XJ900RK, and XJ1100 engines.
$ 89.95
HCP9217 Aftermarket valve guide INSTALLATION TOOL, necessary to properly install the shoulderless valve guides into the head. Use this tool along with the driver tool HCP9216. For all XJ650, XJ700 non-X, XJ750, XJ900RK, and XJ1100 engines.
$ 39.95
HCP9218 Aftermarket valve guide REAMER TOOL. When new valve guides are installed, they should be reamed to a proper size and finish to allow the specified valve-to-guide clearance and insure proper lubrication, but no oil suction through the guides. For all XJ650, XJ700 non-X, XJ750, XJ900RK, and XJ1100 engines.
$ 129.95
HCP9235 Aftermarket valve guide REMOVAL AND INSTALLATION DRIVER TOOL, properly sized to remove original pressed-in valve guides without damaging the head, as well as to drive the guide installation tool HCP9233 used to install new guides. For all XJ700-X and XJ750-X engines.
$ 34.95
HCP9233 Aftermarket valve guide INSTALLATION TOOL, necessary to properly install the shoulderless valve guides into the head. Use this tool along with the driver tool HCP9235. For all XJ700-X and XJ750-X engines.
$ 29.95
HCP9230 Aftermarket valve guide REAMER TOOL. When new valve guides are installed, they should be reamed to a proper size and finish to allow the specified valve-to-guide clearance and insure proper lubrication, but no oil suction through the guides. For all XJ700-X and XJ750-X engines.
$ 89.95
These medium-grit, flexible HONES are just what’s needed to apply a proper “clean-up” cross-hatch finish to a set of valve guides. Hundreds of balls of round coarse-grit oxide are attached to flexible twisted-wire shafts, which when chucked into a 3/8” or 1/2” chuck standard drill (or drill press) can be used to break the cylinder wall glaze and eliminate any high spots on the cylinder wall, creating a fresh surface finish that allows rings to seat properly, insuring the highest compression and lowest oil migration. These hones will not remove metal (and are not designed to do so). Proper use requires the application of honing oil and precise control of hone rotation and linear (in-and-out) speed of motion. Just a few passes is all that’s needed , and it’s remarkably easy to use ---- its self-centering action allows you to produce a beautiful and professional guide wall finish even for a first-time user!
The use of these hones will greatly increase the success of your engine rebuild, and should be considered a “must-have” tool if your are not having your guides actually bored and/or refinished by a machine shop.
HCP23524SET Aftermarket cylinder head VALVE GUIDE HONE, proper size for use on all XJ550 and 1984-85 F600 engines. Includes a bottle of honing oil.
$ 49.95
HCP23525SET Aftermarket cylinder head VALVE GUIDE HONE, proper size for use on all XJ650, XJ700 air-cooled, XJ750 air-cooled, XJ900, and XJ1100 engines. Includes a bottle of honing oil.
$ 49.95
HCP23522SET Aftermarket cylinder head VALVE GUIDE HONE, proper size for use on all XJ700 water-cooled and XJ750 water-cooled engines. Includes a bottle of honing oil.
$ 59.95
Dowel Pin and Collar Puller Tool Kit:
HCP27430 Aftermarket engine DOWEL PIN PULLER tool kit………what a great little tool to have on hand. Those dowel pins or collars are everywhere on these engines: cylinder heard-to-jugs, jugs-to-upper crankcase, side covers-to-crankcase, crankcase lower-to-upper section, and I’m probably forgetting a few. After time and moisture do their trick, those pins can get stuck….really stuck. And though vise grips (and penetrating oil, and heat, and a bigger hammer…) might work on some of them, these tools make for a quick, easy, and safe extraction. Special split collects fit snugly down over the protruding section of the pin, and with the torque bar or a slide hammer attachment tool, you’ll easily twist or yank them right out! Includes 5 different size collects, which are the correct size to attack almost every pin or collar on these engines. Each;
$ 59.95
Straightedge:
HCP23533 Surface measuring PRECISION STRAIGHTEDGE. This 18” straightedge is used by professional engine builders / machine shops for measuring any warpage in flat surfaces. We recommend the purchase of our HCP6383 feeler gauges to be used with this straightedge. Comes with a usage guide and warpage specifications for all XJ cylinder heads. NOTE: although Yamaha does not specify doing so, we also suggest that you measure the mating surface of the cylinder jugs in the same manner as you would with the heads, and apply the same criteria and warpage specifications and remedies to them.
$ 149.95
NOTE: the HCP23533 tool above is available for short term rental, 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.
Piston and Piston Ring Tools:
HCP23597 Aftermarket piston base HOLDER TOOL. Flat slotted tool protects the piston skirts from flopping around and getting damaged while removing or installing the cylinder jugs. You'll need to use two (2) per engine. For all XJ-series engines. Each:
$ 17.95
HCP9771 Aftermarket piston ring COMPRESSOR TOOL. Wide-band ring compressor tool has a quick-release handle and allows you to prevent damage to the rings when installing the cylinder jugs down over the pistons. You'll need to use two (2) per engine. Fits all XJ-series engines. Each:
$ discontinued
NOTE: THE FOLLOWING TOOL IS 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.
HCP23162 Aftermarket piston ring COMPRESSOR TOOL SET. Special spring-steel compressor “clamps” prevent ring damage during cylinder installation, and are easily removed after the cylinder jugs are in position. Supplied with clamp ring compressor tool and 4 clamping rings (one each of 4 different sizes) which will allow use on all XJ- and XS-series engine sizes. Comes with a storage case. Since the 4-cylinder Yammy motors require placing 2 pistons into the jugs at a time, you will need 2 of these tool kits to accommodate your rebuild. Each tool set:
$ 27.95
Cylinder Hones:
These medium-grit, flexible CYLINDER HONES are just what’s needed to apply a proper “clean-up” cross-hatch finish to a set of cylinders before installation of original or new rings. Hundreds of balls of round coarse-grit oxide are attached to flexible twisted-wire shafts, which when chucked into a 3/8” or 1/2” chuck standard drill (or drill press) can be used to break the cylinder wall glaze and eliminate any high spots on the cylinder wall, creating a fresh surface finish that allows rings to seat properly, insuring the highest compression and lowest oil migration. These hones will not remove metal (and are not designed to do so, nor will they typically remove the top-of-cylinder carbon build-up “ridge”). Proper use requires the application of honing oil and precise control of hone rotation and linear (in-and-out) speed of motion. Just a few passes is all that’s needed , and it’s remarkably easy to use ---- its self-centering action allows you to produce a beautiful and professional cylinder wall finish even for a first-time user!
The use of these hones will greatly increase the success of your engine rebuild, and should be considered a “must-have” tool if your are not having your cylinders actually bored and/or refinished by a machine shop.
HCP22811SET Aftermarket engine CYLINDER HONE, proper size for use on all XJ550 engines. Includes a bottle of honing oil.
$ 69.95
HCP22812SET Aftermarket engine CYLINDER HONE, proper size for use on all XJ650 engines. Includes a bottle of honing oil.
$ 79.95
HCP22813SET Aftermarket engine CYLINDER HONE, proper size for use on all XJ700 air-cooled and XJ750 air-cooled engines. Includes a bottle of honing oil.
$ 79.95
HCP22814SET Aftermarket engine CYLINDER HONE, proper size for use on all XJ700 water-cooled, XJ750 water-cooled, and all XJ900 engines. Includes a bottle of honing oil.
$ 79.95
HCP22815SET Aftermarket engine CYLINDER HONE, proper size for use on all XJ1100 and XS1100 engines. Includes a bottle of honing oil.
$ 84.95
HCP22816 Aftermarket engine cylinder hone HONING OIL, this is the proper lubricant to use with any of the above cylinder hones. 1/2 pint bottle is enough to do multiple engines.
$ 17.95
Bearing Clearance Measurement:
Bearing oil clearances are critical for engine longevity. Clearances are measured via the use of a thin, crushable plastic “bead” which is positioned between the bearing and the journal, and which is then crushed when the parts are torqued to proper specifications. The parts are then separated, and the width of the crushed plastic strips are compared against a (included) reference chart. This is a simple, accurate, yet very time-consuming task, but it must be done to insure that you engine assembly is done properly!
These measurements should be done for all bearing positions on the crankshaft main journals, the crankshaft rod journals, and all camshaft journals.
HCP23534 Aftermarket BEARING CLEARANCE MEASUREMENT STRIP, contains a single 12” length of the green plastigauge strip, used to measure clearances between 0.001 - 0.003" (0.025 - 0.076 mm), which covers most (but not all) specified clearances for all XJ550 thru XJ1100 / XS1100 crank, rod, and camshaft bearings. Two strips will be enough to check one engine. Each:
$ 9.95
HCP23535 Aftermarket BEARING CLEARANCE MEASUREMENT STRIP, contains a single 12” length of the red plastigauge strip, used to measure clearances between 0.002" - 0.006" (0.051 - 0.152mm), which covers most (but not all) specified clearances for all XJ550 thru XJ1100 / XS1100 crank, rod, and camshaft bearings. Two strips will be enough to check one engine. Each:
$ 9.95
HCP23536 Aftermarket BEARING CLEARANCE MEASUREMENT STRIP, contains a single 12” length of the blue plastigauge strip, used to measure clearances between 0.004" to 0.009" (0.102 - 0.229mm). Not typically needed for these engines, as such large clearances are outside of allowable specification for any of these XJ engines. Each:
$ 9.95
HCP23537 Aftermarket BEARING CLEARANCE MEASUREMENT STRIP, contains a single 12” length of the yellow plastigauge strip, used to measure clearances between 0.009" to 0.020" (0.229 - 0.250mm). Not typically needed for these engines, as such large clearances are outside of allowable specification for any of these XJ engines. Each:
$ 9.95
HCP23589 Aftermarket BEARING CLEARANCE MEASUREMENT KIT, contains an assortment of green (2), red (2), blue (1), and yellow (1) plastigauge strips, enough to measure clearances in a couple of engines. Includes a clearance specification sheet (showing specified clearances for all XJ550 - XJ1100 engines) and instructions for usage.
$ 24.95
Thread Taps:
c9) Aftermarket THREAD CHASER AND CLEAN-UP TAPS. The aluminum crankcase 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).
HCP28122 Aftermarket engine components THREAD CHASER TAPS SET. This complete set of 3 taps contains all of the different sizes of threads found on all XJ550, FJ600, FZ600, YX600, and XJ600 engines. Almost all threaded have will exhibit some type of thread wear (distortion) or minor injury that should be repaired. Running thread taps thru all of the threaded holes in the 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 engine case cover holes, valvecover bolt holes, cam bearing caps holes, tach drive housing holes in head, cam chain tensioner holes in jugs, exhaust port stud holes in head, intake manifold holes in head, cam chain tunnel stud holes, crankcase cinching bolt holes, cylinder head stud holes (in upper crankcase), spark plug holes in the head, and many others, Comes with a can of cutting fluid and a t-handle tap holder tool. NOTE: due to the expense of this kit, and the reality that you will use these 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!
$ 59.95
HCP28123 Aftermarket engine components THREAD CHASER TAPS SET. This complete set of 4 taps contains all of the different sizes of threads found on all water-cooled XJ700-X, XJ750-X, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 and 1988 FZ750, 1987 FZR750R, and 1987-88 FZR1000 engines. Almost all threaded have will exhibit some type of thread wear (distortion) or minor injury that should be repaired. Running thread taps thru all of the threaded holes in the 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 engine case cover holes, valvecover bolt holes, cam bearing caps holes, tach drive housing holes in head, cam chain tensioner holes in jugs, exhaust port stud holes in head, intake manifold holes in head, cam chain tunnel stud holes, crankcase cinching bolt holes, cylinder head stud holes (in upper crankcase), spark plug holes in the head, and many others, Comes with a can of cutting fluid and a t-handle tap holder tool. NOTE: due to the expense of this kit, and the reality that you will use these 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!
$ 79.95
HCP28124 Aftermarket engine components THREAD CHASER TAPS SET. This complete set of 3 taps contains all of the different sizes of threads found on all XJ650, XJ700 air-cooled, XJ750 air-cooled, XJ900, XJ1100, and XS1100 engines. Almost all threaded have will exhibit some type of thread wear (distortion) or minor injury that should be repaired. Running thread taps thru all of the threaded holes in the 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 engine case cover holes, valvecover bolt holes, cam bearing caps holes, tach drive housing holes in head, cam chain tensioner holes in jugs, exhaust port stud holes in head, intake manifold holes in head, cam chain tunnel stud holes, crankcase cinching bolt holes, cylinder head stud holes (in upper crankcase), middle drive gear output flange holes, spark plug holes in the head, and many others. Comes with a can of cutting fluid and a t-handle tap holder tool. NOTE: due to the expense of this kit, and the reality that you will use these 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!
$ 74.95
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.
HCP11028 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 m8 x 1.25 pitch is a very common sized thread.
$ 9.95
- XJ550, FJ600, XJ600, FZ600, and YX600 Radian cylinder head long studs (in the upper crankcase) mounting holes.
- XJ1100 and XS1100 models cylinder head exhaust port stud holes.
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolt holes (note: some of the mounting holes are a different size, and require the use of the smaller HCP2399 tap above).
- XJ1100 and XS1100 models cylinder head exhaust port stud holes.
- exhaust collector input (from header pipe) pinch clamp (on models using the HCP2181, HCP3925, HCP3927, or HCP3928 sized bolts).
- exhaust collector output pinch clamp (for muffler) for models used the HCP3925 or HCP4623 size bolts.
- XJ650 Turbo models, for the exhaust collector stud holes in the turbo housing.
- XJ650 Turbo models, for the threaded stud holes in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt hole in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt holes in the turbo housing exhaust port (for mounting of the vacuum actuator “can” to the turbocharger).
- exhaust collector rear mounting bracket holes (in frame) on all models used a cast-iron exhaust collector.
HCP28120 Aftermarket THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For the following holes:
- XJ700-X, XJ750-X, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 and 1988 FZ750, 1987 FZR750R, and 1987-88 FZR1000 cylinder head long studs (in the upper crankcase) mounting holes.
$ 11.95
HCP26760 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 other areas of the bike. This m10 x 1.25 pitch is used on a few other places on the bike.
$ 14.95
- XJ650, XJ700, XJ750, XJ900, XJ1100, and all XS1100 models cylinder head long studs (in the upper crankcase) mounting holes.
- all XJ models left side mirror stalk receiver.
- exhaust collector rear mounting bracket bolt threaded collar (the single bolt that passes thru the flange on the collector) on all models used a cast-iron exhaust collector.
- all XJ1100 and XS1100 models exhaust hanger bolt holes.
- threaded holes for any fasteners associated with the following part numbers: HCP2250, HCP3929, HCP3930, HCP3931, HCP3936, HCP3937, HCP3938, HCP4049, HCP19940, and HCP21872.
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
c9a) 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.
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.
HCP28261 Aftermarket THREAD CHASER DIE, for m8 x 1.25 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
- XJ550, FJ600, XJ600, FZ600, and YX600 Radian cylinder head long studs (in the upper crankcase).
- All XJ550 - XJ1100 and XS1100 models engine upper-to-lower crankcase cinch bolts (note: some of the mounting holes are a different size, and require the use of the smaller HCP28260 die above).
- Some models: cylinder head cam chain tunnel-to-cylinder jugs cinching studs, for engines that have a single stud on both the front and rear of the tunnel (models with dual tunnel studs use the HCP28260 die listed above).
- Some models: cylinder head-to-cylinder jugs cinching studs, at the rear of the head (note these are not the cam chain tunnel studs.
- All shaft-drive models: middle gear output flange-to-crankcase bolts.
- XJ1100 and XS1100 models: middle gear drive housing-to-crankcase mounting bolts.
- XJ1100 and XS1100 models cylinder head exhaust port studs.
- exhaust collector input (from header pipe) pinch clamp cinch bolt (on models using the HCP2181, HCP3925, HCP3927, or HCP3928 sized bolts).
- exhaust collector output pinch clamp cinch bolt (for muffler) for models used the HCP3925 or HCP4623 size bolts.
- XJ650 Turbo models, for the exhaust collector stud in the turbo housing.
- XJ650 Turbo models, for the threaded studs in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt used into the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolts used (for mounting of the vacuum actuator “can” to the turbocharger.
- exhaust collector rear mounting bracket bolts (which thread into the frame) on all models used a cast-iron exhaust collector.
- For any fasteners associated with the following part numbers: HCP2181, HCP2942, HCP3925, HCP3927, HCP3928, HCP3934, HCP3939, HCP4208, HCP4623, HCP4956, HCP6156, HCP16101, and HCP16244.
HCP28575 Aftermarket THREAD CHASER DIE, for m9 x 1.25 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although not 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:
$ 8.95
- XJ700 water-cooled and XJ750 water-cooled engines, cylinder head-to-upper crankcase long studs
HCP28577 Aftermarket THREAD CHASER DIE, for m10 x 1.25 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although not 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:
$ 8.95
- exhaust collector rear mounting bracket bolt (the single bolt that passes thru the flange on the collector) on all models used a cast-iron exhaust collector.
- all XJ1100 and XS1100 models exhaust hanger bolts.
- For any fasteners associated with the following part numbers: HCP2250, HCP3929, HCP3930, HCP3931, HCP3936, HCP3937, HCP3938, HCP4049, HCP19940, and HCP21872.
HCP28579 Aftermarket THREAD CHASER DIE, for m12 x 1.25 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although not 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:
$ 8.95
- Many models: rear engine mounting bolts
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
Cooling System Tools:
HCP9236 Aftermarket waterpump MECHANICAL SEAL INSTALLER TOOL, nice copy of the original Yamaha specialty tool used on all the XJ700-X and XJ750-X water-cooled models.
$ 79.95
Miscellaneous Tools:
HCP25903 Aftermarket STAINLESS STEEL WIRE-BRISTLE CLEANING BRUSH, proper size for cleaning out the residue and burnishing the engine rubber insulator (“damper”) mounting holes in the crankcase upper and lower sections. Double-turn wire helix core can be inserted into drill and be used o “hone” the case openings back to a smooth finish. Proper size for all XJ series engines and XS1100 engines..
$ 14.95
ALSO---it's never a bad idea to use some of our 100% Silicone Grease as an "assembly lube" when installing any of these engine insulators as they are a very tight fit when new:
HCP28407 Aftermarket o-ring, oil seal, and gasket installation pure SILICONE GREASE. This small 5-gram (1/6-oz) snap-open "pillow packet" is enough for a few small oil seals, dozens of o-rings, and the like. Each:
$ 4.95
HCP1714 Aftermarket o-ring, oil seal, and gasket installation pure SILICONE GREASE. This generous 14-gram (1/2-oz.) tub goes a long way, because just like Brylcreem, "just a little dab will do ya'!" Each:
$ 9.95
EXHAUST 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.
Prevent any of the above situations from happening to you by using one of our anti-seize products when installing your new bolts!
it54) Aftermarket broken stud EXTRACTOR TOOL KIT. Common problem: you snap or shear off the head of a fastener, now what do you do? Prevent these situations from happening to you by using one of our anti-seize products when installing new bolts or studs!
HCP10302 Aftermarket 6mm BROKEN STUD EXTRACTOR......this is the correct size for both the exhaust headpipe studs and the intake manifold bolts in the cylinder head, which are the most common fasteners that you'll need to use these extractor tools on. You simply pound this extractor onto the stud, and then use an open-end wrench to twist it out. As long as you have a bit of the broken stud remaining outside of the cylinder head threaded hole (in other words, the fastener has not broken off "flush"), then this tool is what's going to save your day. Similar in concept to a "ez-out", but these tools have their "biting" surfaces on the inside of a socket-type housing, so that the hardened steel ridges bite into the stud and allow you to extract it. Also works great on screw or bolt heads that have had the drive slot ruined or the bolt head rounded off.
$ 69.95
HCP26979 Aftermarket complete STUD EXTRACTOR and INSTALLATION TOOLS SET. Complete set of 3 different size tools, these are an upgraded version of the “two locking nuts” method of stud extraction or installation, and their small size allows them to work easily in cramped spaces. Note that this type of tool requires that you have decent threads on the end of the stud:
www.youtube.com/watch?v=NNH7u87dhng
This set has the proper sized tools to install and remove exhaust manifold studs, cylinder head and cylinder jug studs, the long cylinder head-to-crankcase studs (all models except XJ700-X and XJ750-X engines), broken intake manifold bolts and many other threaded studs (or headless bolts) on the engine and drivetrain. Contains one each M6 x 1.00 pitch, M8 x 1.25 pitch, and a M10 x 1.25 pitch tool.
$ 29.95
HCP10301 Aftermarket complete STUD EXTRACTOR TOOLS SET. Complete set of 4 different size extractors, and these can be used with ratchet wrenches for ease of removal. These are “roller clutch” type removers that use internally locking rollers to grip and turn the stud. This type tool will damage the threads as part of the removal process, and although it’s possible to use them on broken threads (the smooth shank portion of the stud, even if that is all that is present i.e. the stud or bolt has snapped off and all that remains is the unthreaded portion), they don’t always work all that well on smooth surfaces…..but this also means that the can also be used on dowel pins and some guide collars. Note that these stud removers are much larger is physical size that the HCP26979 tools, which may present problems in restricted areas:
www.youtube.com/watch?v=aE5VnScjRcI
This set has the proper sized tools to remove exhaust manifold studs, broken intake manifold bolts, cylinder head and cylinder jug studs, the long cylinder head-to-crankcase studs (all models except XJ700-X and XJ750-X engines), and most other threaded studs (or headless bolts) on the engine and drivetrain. Contains one each of a 6mm and 8mm extractors (which can be used with 3/8" drive ratchets) and one each of a 10mm and 12mm extractors (which can be used with 1/2" drive ratchets). You simply pound the extractor onto the stud, and then use an appropriate sized ratchet wrench to twist it out. Comes in a molded storage case.
$ 79.95
Or, you can put the power of chemistry to work for you:
https://tap-die.com/contents/en-uk/d296_Tip_Remove_Broken_Tap_Drill_Reamer_Tap_and_Die_Co.html
Alum powder, get it at your local supermarket:
https://www.walmart.com/ip/McCormick-Alum-1-9-oz/10535117
c9a) THREAD CHASER TAPS and DIES. Over time, rust and it seizure effects can cause fastener threads to become pitted and result in sloppy fits and un-reliable torque readings……besides making assembly and dis-assembly a pain in the tailpipe and risky. Out line of THREAD CHASING TAPS (for threaded holes) and CHASER DIES (fot the bolt or screw fasteners) are used to clean, restore, and repair threads on the such items. These tools help restore that like-new feel to used fasteners and their accepting holes, and will straighten and restore threads to allow for proper torque settings to be achieved and maintained.
Taps can be manipulated with a proper sized wrench on the square shank of the tap, or for more secure result, use our HCP28170 TAP HANDLE, featuring offset handles and fully adjustable head for all m3-m12 size taps. 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……..
And unlike standard round dies, ours 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 do, and when you’re done you’ll be glad you took the time to do the job properly!
Always lubricate the tap or die tool (or fastener) with a light oil or grease during use, or use one of our specialty THREAD CUTTING FLUIDS listed further below.
The following professional quality tool-steel metric cutting taps and dies will allow you to either "clean-up" or re-thread distorted or stripped threads in all metals, soft (aluminum) to hard (steel), and are a great addition to your toolbox.
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
- All XJ550 - XJ900 models cylinder head exhaust port stud holes.
- exhaust headpipe gas test bolt threaded hole in the bottom of each header pipe.
- exhaust collector input (from header pipe) pinch clamp.
- collector chrome cover retaining bolt hole (XJ1100 models)
- collector chrome cover rear retaining screw hole (XJ1100 models).
- XJ650 Turbo models, turbo housing hole for the right muffler “joiner pipe” mounting bolt holes.
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
- 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.
HCP11028 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 m8 x 1.25 pitch is a very common sized thread.
$ 9.95
- XJ1100 and XS1100 models cylinder head exhaust port stud holes.
- exhaust collector input (from header pipe) pinch clamp (on models using the HCP2181, HCP3925, HCP3927, or HCP3928 sized bolts).
- exhaust collector output pinch clamp (for muffler) for models used the HCP3925 or HCP4623 size bolts.
- XJ650 Turbo models, for the exhaust collector stud holes in the turbo housing.
- XJ650 Turbo models, for the threaded stud holes in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt hole in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt holes in the turbo housing exhaust port (for mounting of the vacuum actuator “can” to the turbocharger).
- exhaust collector rear mounting bracket holes (in frame) on all models used a cast-iron exhaust collector.
HCP28261 Aftermarket THREAD CHASER DIE, for m8 x 1.25 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
- XJ1100 and XS1100 models cylinder head exhaust port studs.
- exhaust collector input (from header pipe) pinch clamp cinch bolt (on models using the HCP2181, HCP3925, HCP3927, or HCP3928 sized bolts).
- exhaust collector output pinch clamp cinch bolt (for muffler) for models used the HCP3925 or HCP4623 size bolts.
- XJ650 Turbo models, for the exhaust collector stud in the turbo housing.
- XJ650 Turbo models, for the threaded studs in the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolt used into the turbo housing exhaust port (for mounting of the left muffler to the turbocharger).
- XJ650 Turbo models, for the bolts used (for mounting of the vacuum actuator “can” to the turbocharger.
- exhaust collector rear mounting bracket bolts (which thread into the frame) on all models used a cast-iron exhaust collector.
- For any fasteners associated with the following part numbers: HCP2181, HCP2942, HCP3925, HCP3927, HCP3928, HCP3934, HCP3939, HCP4208, HCP4623, HCP4956, HCP6156, HCP16101, and HCP16244.
HCP26760 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 other areas of the bike. This m10 x 1.25 pitch is used on a few other places on the bike.
$ 14.95
- exhaust collector rear mounting bracket bolt hole (the single bolt that passes thru the flange on the collector) on all models used a cast-iron exhaust collector.
- muffler mounting oval nut.
- all XJ1100 and XS1100 models exhaust hanger bolt holes.
HCP28577 Aftermarket THREAD CHASER DIE, for m10 x 1.25 pitch fasteners. Use on the fasteners for all of the applications listed below (and any other that is the same size; although not 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:
$ 8.95
- exhaust collector rear mounting bracket bolt (the single bolt that passes thru the flange on the collector) on all models used a cast-iron exhaust collector.
- all XJ1100 and XS1100 models exhaust hanger bolts.
- For any fasteners associated with the following part numbers: HCP2250, HCP3929, HCP3930, HCP3931, HCP3936, HCP3937, HCP3938, HCP4049, HCP19940, and HCP21872.
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
STEERING AND SUSPENSION 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.
FORK SYSTEM SERVICE TOOLS:
Assembly and Dis-assembly Tools:
w) Lower Fork Tube DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except XJ600 Seca II, 1981-83 XJ750 Seca, XJ1100, and all XS1100 Special and Midnight Special models. This tool will make the disassembly of your upper tube from the lower tube much easier! NOTE: this tool is available for short term rental, 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.
HCP4402 Aftermarket DAMPER ROD RETAINING TOOL.
$ 29.95
HCP9238 Aftermarket fork upper cap bolt REVERSE HEX SOCKET TOOL. This tool allows the easy removal and installation of the "inverted/reversed" hex-drive cap bolt used on the top of the inner fork tubes on all 1984 FJ600, XJ650 Turbo, XJ700 non-X, XJ750-D, XJ750P (37H) model, and all XJ900RK, RL, N/FN, and F models.
$ 12.95
HCP15939 Aftermarket lower fork tube OIL SEAL DRIVER. split “clamshell” heavy duty design features adjustable inserts that allow it to be used properly and safely install the lower tube oil seals and (where applicable) lower tube dust seals on all 35-43mm fork tubes (which covers the entire XJ- and XS-series line of bikes).
$ 39.95
Fork Tube Cleaning and Polishing:
HCP28489 Fork Tubes DEEP REACH CLEANING BRUSH. This 36" long brush features polyester bristles that will reach deep inside the forks tubes to clean away grit and oil sludge residue that cannot otherwise be reached or disturbed. Has a comfortable easy-grip plastic handle and flexible twisted-wire shaft. .Use with your favorite cleaning solvents to get the insides of the fork tubes free of contaminants.
$ 39.99
ft4) These stainless-steel, bristle-wire DE-BURRING BRUSHES will work wonders on the upper cap bolt area on both the threaded and the non-threaded style of fork tubes. Tubes that use threaded cap bolt (all XJ650 Turbo, all XJ700 models, XJ750-X models, XJ750 Maxim and Midnight Maxim, XJ900RK, and XJ1100 models) should use the HCP10223 butterfly brush; non-threaded tubes can use either the HCP10222 spiral brush or the HCP10223 butterfly brush. Both style brushes have stems that are designed to be used in a standard power drill, and should be used at 850 rpm's or less. These brushes will make quick and meaningful work of the cleaning and polishing of this critical area on your upper fork tubes.
HCP10222 Aftermarket stainless-steel double-density spiral DE-BURRING BRUSH, for use on fork tubes without a threaded cap bolt.
$ 8.25
HCP10223 Aftermarket stainless-steel high-density "butterfly-wings" DE-BURRING BRUSH, for use on fork tubes with or without threaded cap bolts.
$ 8.25
Fork Tube Oil Level Gauges:
HCP1728 Fork tube oil fluid level measurement GAUGE AND SYRINGE. This handy tool makes the measurement of the fork oil level easy and accurate. NOTE: the proper amount of fork oil is determined via the measurement of the fork oil LEVEL (distance below the very top of the inner tube) rather than a volume AMOUNT of oil specification. Too little oil will make the ride mushy, while too much oil makes the ride harsh (and can blow out the oil seals!)
$ 29.95
ffl4) Aftermarket fork oil measurement GRADUATED CYLINDERS. The best way to measure the precise amount of fork oil fluid is via the use of these lab-quality measurement cylinders. Available in either transparent (clear) or translucent (cloudy) durable plastic construction, they all have easy-to-read scale numerals (milliliters) and feature a "non-wetting" inner surface coating that prevents the concave "meniscus" from forming at the top of the fluid, thus insuring a much more accurate level reading. Large bases insure stability while large spouts make "the pour" easy and prevent messy drips. Very useful device to have for front fork oil changes.
HCP10741 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, translucent (cloudy).
$ 11.95
HCP10744 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, transparent (clear).
$ 24.95
HCP10742 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, translucent (cloudy).
$ 12.95
HCP10745 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, transparent (clear).
$ 33.95
HCP10743 Aftermarket fork oil GRADUATED CYLINDER, super-sized 1000ml capacity, translucent (cloudy), with convenient side handle to insure steady pouring.
$ 48.95
Fork Tube Air Pressure Tool and Gauge:
HCP9196 Aftermarket AIR VALVE STEM TOOL, handy 4-in-1 tool allows you to properly remove and insert the stem core, and also clean/chase/re-thread the internal and external stem threads.
$ 4.95
HCP9108 Aftermarket air-assisted forks LOW PRESSURE AIR GAUGE, heavy-duty 0-20 psi pencil (stick) pressure gauge marked in 1/2-psi increments, perfect for checking fork air pressures on models so equipped. Very high quality and much more accurate than standard tire pressure gauges, which is very important on the fork pressures as an imbalance between the fork pressure can lead to steering and stability issues, while too much pressure will blow out the lower tube oil seals!
$ 4.95
Steering Head & Shock Adjuster Tools:
HCP1692 Aftermarket steering head tube BEARING RACE REMOVAL TOOL. This very high quality, split flared-shaft bearing race removal device grasps the edges of the bearing races at four positions and pops them out with ease. Makes a sometimes very frustrating task simple.
$ 49.95
HCP7863 Aftermarket steering stem ring nut and shock absorber ADJUSTER TOOL, heavy-duty chrome plated spanner "wrench" is the correct size to work with all XJ-series bike steering stem ring nuts, as well as fitting the adjuster tab on rear shock absorbers (for those models that have non-air adjustable rear shocks). Very high quality, versatile tool to have in your box.
$ 34.95
HCP28446 Aftermarket steering stem ring nut and shock absorber ADJUSTER SOCKET, heavy-duty aluminum seep-well spanner socket (1/2” drive) makes tightening and proper torqueing of the upper ring nut a breeze (since this is a socket, rather than a "flat wrench", you can attach it to your torque wrench). Works with all XJ-series bike steering stem ring nuts, and probably many other makes/models as well. This is similar to the Motion Pro # 08-0570 spanner nut socket, but it is deep enough to be used on XJ models (since the steering stem protrudes a much greater distance than what the MP tool is designed to be used with). Very high quality, versatile tool to have in your box. This tool is available for rental.
$ 69.95
HCP8041 Aftermarket steering stem Ring Nut ADJUSTER WRENCH, special tanged wrench properly grabs the castellations in the ring nuts and holds firm, preventing the rounding-off of the ring nut when trying to loosen or install them using incorrect tools (such as channel lock pliers). Adjusts to a wide range of sizes to fit most bikes. A professional grade tool.
$ 89.95
Swingarm Tools:
HCP11336 Aftermarket standard depth 27mm SOCKET, used to remove your swingarm pivot bolt and nut on all XJ650 - XJ1100 models, and the rear axle castle nut on XJ1100 and XS1100 models. Chrome-plated, 6-point, 1/2" drive.
$ 12.95
HCP10300 Aftermarket 3/8"-to-1/2" DRIVE ADAPTER. For use with the HCP10298, HCP11336, or HCP20225 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
WHEEL AND TIRE TOOLS:
ld2) Concentrated LEAK DETECTOR FLUID reveals even the smallest of pressure leaks. Spray on the suspected areas......such as exhaust system joints, tire stems and valves, fork air system valves, etc.....and watch for the telltale mad rush of bubbles.
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.
HCP12361 Aftermarket LEAK DETECTOR FLUID, in an 8-ounce non-aerosol bottle. Best to transfer into an old windex spray bottle (etc.) and use with a spray nozzle. Each:
$ 9.95
Wheel Bearing Service Tools:
Sold individually or as a complete shop set, these 'split-collar" SPLIT-COLLAR BEARING PULLERS AND DRIFT TOOLS make removing wheel bearings a pleasure rather than a chore! No more trying to find the proper size and length drift rod and then clumsily using it inside a long, blind tool.........that's just "too" old-skool. These pullers are simply placed within the bearing shaft hole, the drift rod is entered into the split collar slot, you give the rod a good whack with a hammer, and out she comes! Turns a pain-in-the-butt procedure into a 1-minute operation. NOTE: since these pullers work by "grabbing" onto the inner bearing race, once they are used to remove a bearing, the bearing is no longer re-usable.
A fine guide to wheel bearing replacement can be reviewed at:
http://xjbikes.com/forums/index.php?threads/35134
and
http://www.xj4ever.com/wheel bearing replacement.pdf
HCP17851 Aftermarket wheel bearing removal DRIFT ROD, special size tip properly fits all of the split-collar drivers below. You will need only one of these rods regardless of how many different size drivers you will use.
$ 29.95
HCP17853 Aftermarket wheel bearing removal SPLIT-COLLAR DRIVER, proper size for use on all XJ550, XJ650, XJ700, XJ750, and XJ900 front wheel bearings.
$ 16.95
HCP17854 Aftermarket wheel bearing removal SPLIT-COLLAR DRIVER, proper size for use on all XJ550 left inner or right side rear wheel bearings, and all inner and outer rear wheel bearings on all XJ650, XJ700, XJ750, and XJ900 models, as well as on XJ1100 and XS1100 front wheel bearings. NOTE: 1984 XJ750RL Seca and all XJ900 models use a cylindrical bearing on the left inner position, and a bearing puller is not necessary for removal of that bearing.
$ 16.95
HCP17855 Aftermarket wheel bearing removal SPLIT-COLLAR DRIVER, proper size for use on all XJ550 left outer side rear wheel bearing and XJ1100 and XS1100 right side rear wheel bearing.
$ 16.95
HCP17856 Aftermarket wheel bearing REMOVAL TOOLS KIT, one proper size drift and driver for use on all XJ550, XJ650, XJ700, XJ750, and XJ900 front wheel bearings.
$ 44.95
HCP17857 Aftermarket wheel bearing REMOVAL TOOLS KIT, one proper size drift and 2 drivers for use on all XJ550 rear wheel bearings.
$ 59.95
HCP17858 Aftermarket wheel bearing REMOVAL TOOLS KIT, one proper size drift and driver for use on all XJ650, XJ700, XJ750, and XJ900 rear wheel bearings or XJ1100 and all XS1100 front wheel bearings.
$ 44.95
HCP17859 Aftermarket wheel bearing REMOVAL TOOLS KIT, one proper size drift and driver for use on XJ1100 and all XS1100 rear wheel bearings.
$ 44.95
HCP17865 Aftermarket wheel bearing REMOVAL TOOL SET, one proper size drift and the 3 drivers for use on all XJ550 front and rear wheel bearings. NOTE: this kit contains all the drivers to also allow the removal of all front and rear wheel bearings on XJ650, XJ700, XJ750, XJ900, XJ1100, and all XS1100 models.
$ 69.95
HCP17866 Aftermarket wheel bearing REMOVAL TOOL SET, one proper size drift and the 2 drivers for use on all XJ650, XJ700, XJ750, and XJ900 front and rear wheel bearing removal.
$ 59.95
HCP17867 Aftermarket wheel bearing REMOVAL TOOL SET, one proper size drift and the 2 drivers for use on XJ1100 and all XS1100 front and rear wheel bearing removal.
$ 59.95
HCP7850 Aftermarket wheel bearing REMOVAL TOOL SET, heavy-duty complete set of 6 different size split-collar drivers and two drift rods allows you to service any model front or rear wheel bearings on all XJ-series bikes and many other models.
$ 74.95
it56) Aftermarket specialty SOCKETS and ADAPTERS are for specific-use purposes as described below.
HCP22023 Aftermarket extended depth 19mm SOCKET, used to remove the front wheel axle castle nut on XJ750RL and XJ900 models, and the rear axle castle nut on XJ650, 1981-83 XJ750, and XJ900 models. Chrome-plated, 6-point, 3/8" drive.
$ 11.95
HCP22024 Aftermarket extended depth 22mm SOCKET, used to remove the front wheel axle castle nut on XJ550, XJ650, 1981-83 XJ750, XJ1100 and XS1100 models, and the rear axle castle nut on XJ550, XJ700, and XJ750-X models. Chrome-plated, 6-point, 3/8" drive.
$ 9.95
HCP11336 Aftermarket standard depth 27mm SOCKET, used to remove your swingarm pivot bolt and nut on all XJ650 - XJ1100 models, and the rear axle castle nut on XJ1100 and XS1100 models. Chrome-plated, 6-point, 1/2" drive.
$ 12.95
HCP10300 Aftermarket 3/8"-to-1/2" DRIVE ADAPTER. For use with the HCP10298, HCP10299, HCP10530, HCP11336, or HCP22025 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
Wheel Service Tools:
HCP12960 Aftermarket wheel ROLL STAND. This nifty little device is specially designed for people who do not have a centerstand, as it allows the wheel/tire unit to be rotated as if the rear wheel was off of the ground.......even though it's not, as the tire is setting on this small square "stand" that has free-spinning rollers front and back (sort of like a chassis dyno). So you can roll the rear wheel into this "stand", but the bike on the side stand, and rotate the wheel/tire unit for chain maintenance (550 models) or other such activities. NOTE: not designed for operating the rear wheel under engine load!
$ 79.95
Tire Mounting Tools:
Here's a variety of tools to make the chore of tire dis-mounting and mounting of your tires just a wee bit easier (and much less expensive than having a dealership perform these tasks!).
HCP12959 Aftermarket portable TIRE CHANGING STAND. Looks like a small, short stool, and allows you to lay the wheel (with brake rotors or rear sprocket still installed) onto the stand, getting it up off the ground, and holds the wheel securely-----allowing you to lever the tire onto or off of the rim easily (without having to fight a moving wheel). Can be used on all XJ-series wheels.
$ 149.95
HCP1753 Aftermarket tire BEAD POPPER, this molded plastic wedge, when firmly whacked with a mallet or hammer, gently "pops" stuck tire beads away from the inner rim flange without risking damage to the wheel rim in this critical area.
$ 24.95
HCP1754 Aftermarket tire BEAD SETTER. This large, tough molded rubber donut "o-ring", when placed between one lip of the tire and the rim, allows a tire to be inflated and the beads set "automatically" (instead of having to struggle trying to hold both tire beads against the rim). As soon as the opposite bead sets against the rim, the rising air pressure forces this bead setter out from the other side, thus seating the beads easily, quickly, and with a minimum of effort. For 16" wheels as used on the rear of all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, and XJ1100 models.
$ 109.95
HCP1755 Aftermarket tire BEAD SETTER. This large, tough molded rubber donut "o-ring", when placed between one lip of the tire and the rim, allows a tire to be inflated and the beads set "automatically" (instead of having to struggle trying to hold both tire beads against the rim). As soon as the opposite bead sets against the rim, the rising air pressure forces this bead setter out from the other side, thus seating the beads easily, quickly, and with a minimum of effort. For 18-19" wheels as used on the front or rear of all XJ-series bikes.
$ 109.95
HCP1750 Aftermarket TIRE SPOON, 10" cupped "spoon" is safer to use on tubed tires than the tire irons listed below when removing the tire from the wheel. Plastic handle.
$ 21.95
HCP1751 Aftermarket TIRE SPOON, 16" cupped "spoon" is safer to use on tubed tires than the tire irons listed below when removing the tire from the wheel. Aluminum handle.
$ 39.95
HCP9772 Aftermarket CURVED TIRE IRON, 15" cast steel tire "pry bar" helps you lever the wheel bead over the edge of the tire safely and without risking damage to your wheel rims or the tire. You will need to use 2-3 tire irons (a mix of straight and curved versions) to mount a tire.
$ 17.95
HCP9773 Aftermarket STRAIGHT TIRE IRON, 16" forged steel tire "pry bar" helps you lever the wheel bead over the edge of the tire safely and without risking damage to your wheel rims or the tire. You will need to use 2-3 tire irons (a mix of straight and curved versions) to mount a tire.
$ 17.95
HCP1749 Aftermarket pair of nylon RIM EDGE PROTECTORS, these curved plastic guards, placed under the above tire irons, provide the utmost in protection from rim edge damage when changing tires.
$ 14.95
HCP9196 Aftermarket VALVE STEM TOOL, handy 4-in-1 tool allows you to properly remove and insert the stem core, and also clean/chase/re-thread the internal and external stem threads.
$ 4.95
HCP23811 Aftermarket PIVOTING-HEAD AIR CHUCK, heavy-duty air chuck features a fully pivoting head with allows easy access in tight spaces!. Very high quality aluminum body has standard 1/4” NPT internal female threads which allows use with all standard air hose couplers and fittings.
$ 39.95
HCP23817 Aftermarket high performance DIGITAL AIR PRESSURE GAUGE, heavy-duty, battery-powered digital display air pressure gauge display pressures in 0.1psi increments and is accurate to +/- 0.6psi at any pressure reading. Round aluminum body has a shock-resistant rubber boot, large back-lit easy to read LED display, push-button pressure-release valve, 18” long rubber hose with dual swivels and a brass ball-type air chuck. Very high quality and much more accurate than standard tire pressure gauges, this gauge makes checking your tire pressure a job you’ll look forward to doing.
$ 89.95
Wheel Balancing Tools:
HCP10490 Aftermarket WHEEL BALANCER. Contrary to popular belief, you don't have to spin-balance motorcycle wheels to achieve satisfactory results. With this simple tool, and a pair of hi-rise common jackstands ("hi-rise" means more than 15" lift off the floor level), you can professionally balance your own tire/wheel assembly. High quality tool-steel axle, low-drag bearings, and precision-machined wheel holder collets provide you with the means to spin-balance all XJ-series wheels in a matter of minutes. Set-up and balancing directions are included. Properly cared for (meaning: don't drop it or beat on it!), this balance will last a lifetime. WARNING: this device (and your knowledge of how to use it correctly) will tend to make you real popular with other bike owners............
$ 119.95
HCP12956 Aftermarket clip-on weight INSTALLATION and REMOVAL TOOL, for use with OEM or aftermarket clip-on style wheel weights only. For all XJ-series bikes. Each:
$ 11.95
HCP12955 Aftermarket clip-on weight INSTALLATION and REMOVAL TOOL, for use with OEM or aftermarket clip-on style wheel or spoke weights. For all XJ-series bikes. Each:
$ 17.95
HCP12957 Aftermarket stick-on weight REMOVAL TOOL, for use with OEM or aftermarket stick-on style wheel weights only. For all XJ-series bikes. Each:
$ 3.95