Fuel Tank liner(?) issues on new shiny '82 XJ750 Maxim

Wintersdark · Oct 18, 2017

TheCrazyGnat said: ↑

Well, I was going to cds1984's post here , but I see his pictures are gone. It doesn't look like they point to photobucket, so maybe there is hope they will be restored. That having been said, I did this last year and was able to get through without too much trouble. I did buy both the haynes and FSM, but I used the Haynes much more. I would still recommend getting the FSM though, there were a few times when I had both out in front of the bike when I was having trouble comprehending what exactly I was supposed to do.

For the most part, there aren't too many special tools needed: You'll need torx drivers for the 6(?) of those that are in the engine, the rotor pulling tool, torque wrenches in both inch and foot lbs, and a clutch basket holding tool might be helpful, but I did without that. You'll need the gaskets for the clutch cover, alternator cover, oil sump, etc. and Loctite 515/518 for the case halves.

Like Matti said, the chain guides are known to fail due to age. I would absolutely install a new one regardless. I went ahead and just replaced all the rubber/plastic in there.

One thing that I would make sure to do (cds1984 mentions this in his writeup) is leave the rear wheel/brake on until after you have the stator, rotor, and clutch completely removed. You can use it as an anchor and makes the process a lot easier.

As always, the folks around here are an incredibly valuable resource. Make sure to ask questions if you aren't sure about something. I did take a lot of pictures when doing this myself. They were mostly with my phone, so they aren't super great, but they made good reference points.

Good luck!
Click to expand...

Thanks! I noticed in cds's post he FULLY disassembled the motor, including the top end. Is that necessary?

Obviously, I'd prefer to not disturb the top end of that's possible.

TheCrazyGnat · Oct 18, 2017

Wintersdark said: ↑

Thanks! I noticed in cds's post he FULLY disassembled the motor, including the top end. Is that necessary?

Obviously, I'd prefer to not disturb the top end of that's possible.
Click to expand...

Yeah, he went all the way! You do not need to remove the head to split the cases.

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Fuel Tank liner(?) issues on new shiny '82 XJ750 Maxim

Wintersdark Well-Known Member

TheCrazyGnat Well-Known Member

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