Yamaha XJ650 Part 25 Engine Overhaul

[@SoBoring136]

Thank god some one else uses 100% mineral oil for proper break in. I’ve had arguments with qualified engine builders about this and can’t believe anyone would use synthetic oil to bed the rings. Awesome you have a new subscription

[@Mezzmoengineering]

Thanks mate, yep, mineral oil allows a bit more friction to allow the rings to bed in properly. Synthetic is the go once its all run in.....

[@jefferynelson]

20:12 thank you !! been trying to get a picture of what the YICS actually is

[@clickireland1113]

NOTICE: Spray Nozzle Orientation. This just a note for anyone who runs at a rebuild with excitement and could miss this one small important orientation. It might be obvious to most viewers but just in case: That spray nozzle (5.39 in this video) must be oriented so it's hole matches its crankcase hole brother; which you can see looking inside the tube in the crankcase where the spray nozzle goes. Also which might be obvious: Passage clearance of this nozzle. Properly best to ultrasonic clean (or similar solvent soak / clean / air blast) this nozzle to ensure its passage for oil is clear and good. Wear the safety glasses guys (and gal). The actual spay hole is not large. And Primary chains are expensive enough and replacement not a stamp lick as we can see. Great video.

[@Mezzmoengineering]

Good tips mate

[@BroadcastingEd]

My bike (82 XJ650) has been dead for over a year and needs to be completely pulled apart to clean out the chunks of clutch basket that jammed up the transmission. This video is giving me the confidence to actually dig in to that project so I can ride again next summer.

[@Mezzmoengineering]

Great to hear. Good luck with your build

[@jishh]

Love the attention to detail in this build! I have done my rocker cover in the same finish too ✌️

[@Mezzmoengineering]

Thanks Jish, hoping to get out on a first ride sometime soon.....Still a lot left to do though...

[@r779projects7]

Both of you are inspirations. If my engine turns out half as nice.....! I used an xv1100 swing arm to mount the xj900 rear rim. The bike is an xj650 with the R1 front so the 900 rear gives me an almost matching 3 spoke and the 1100 swing gives me just a little longer wheel base. This did take some careful grinding. I read the xj700 non X cams are the most aggressive I will try these eventually but I have learned so much from this I am grateful for that. Thank you Mezzmo thank you Jish awesome job! XJBIKES!!!

[@lwoodt1]

Attention to every detail is the key to success.

[@johnpaulmakowski7464]

another excellent detailed video from Mezzmo!

[@Mezzmoengineering]

Thanks mate

[@lukeperhaps2734]

Hey Mezzmo, this is the best engine video around and has helped me tremendously. One error though, the seal on the trans countershaft bearing should face inwards. This bearing receives pressurized lube via the bearing retainer cover from the outside. With the seal facing out, it only will receive splash lube from the gear side.

[@Mezzmoengineering]

@@lukeperhaps2734 Thanks mate, glad you liked it. Interesting about the bearing, I thought the same however it was that way originally from the factory. See it in the pull down video. I figured it was fine after 100k so decided to put it back the same way. Really not sure why they bothered even putting a seal on one side

[@lukeperhaps2734]

​@@MezzmoengineeringYep looks like the factory must have got it backwards. I think the reason for the seal is to add a little back pressure as the same lube oil is diverted into the hollow gearshaft to lube all its bits also. Your entire series on this bike is top notch.

[@Mezzmoengineering]

​@@lukeperhaps2734 Thanks, I appreciate the comments and also like discussing things like design, errors, possible improvements etc. Cheers👍

[@bearwood85]

Edit work and intro was a nice touch for this vid.... Attention to detail as always Mezzmo 👌🏽👌🏽👌🏽

[@Mezzmoengineering]

Glad you liked it!

[@MattysWorkshop]

Coming along beautifully,

[@1995simas]

I was looking for a problem with my xj900 and it doesn't turn on the 5th gear but instead turns on neutral... I realized I had put the middle fork in the opposite direction... I will try fix it by removing oil pan. Sometimes we all make mistakes. Without your video I wouldn't have found out. Thank you! 😄

[@Mezzmoengineering]

Hi mate, glad it helped you out.

[@carrollbj9768]

You've made a really excellent machine there - thank you for the clear and very informative content - you make it look so easy :-)

[@Mezzmoengineering]

Thanks for the feedback

[@pantherzzz111]

Thanks again for the reply, you are a gentleman, cheers mate.

[@pantherzzz111]

Hi mate, Great videos, restoring an xj650 myself, parts are getting hard to source now, one of the gearbox bearings in the crank case is closed in, is a blind bearing puller the only way to get it out, many thanks and thanks for the videos.

[@Mezzmoengineering]

Hi, not sure of the bearing you're referring to but I got them all out without any puller. Let me know exactly which bearing and I'll tell you how to remove it

[@shawnmrfixitlee6478]

Great job , Looks awesome . Bet it will run perfect ! ENJOYED..

[@clickireland1113]

Spray Nozzle Update: Just noticed a pic of a new primary chain spray nozzle shows a location pin extruding from the head. This must be what locates in the slot that's in the opening of the crankcase where the nozzle goes. I reckon without this, a nozzle can vibrate over time to an off-location. Reducing or fully negating its operational function. Something to consider if you are re-building with a re-use nozzle.

[@Mezzmoengineering]

Hi Mate, yes that pin goes into a slot of the crankcase to ensure the hole is pointing the right way. I forgot to show that detail in the video. Then the cover is whats holds it in.

[@clickireland1113]

@@Mezzmoengineering Ah no worries. The nozzle ideally has a pin to guide but mine didnt. Hence the comment. I don't know what kinda guy was in here before me the poor fella. Clutch nut undid by fingertips. Cyl. No.2 con rod missing a bearing shell. I'm missing a SHED!

[@erasmomarroquin3079]

Great vídeo!

[@obs301]

Cannot believe this video only has 4k views

[@Mezzmoengineering]

More views would be nice, spread the word

[@diegoaespitia]

hey mate, sorry to ask you another question but ive been working on a 650, putting on a split timing chain like you. problem is, i cant find a riveting tool small enough for the cam chain. most rivet tools are for drive chains. How did you peen that cam chain master link at 22:25 ?

[@Mezzmoengineering]

Hi mate, I just placed a hammer behind the link to support it and then used a pin punch and another hammer to peen them over manually. No need for special tools....

[@alfredvradenburg2689]

That's nuts!!! I'm rebuilding my 1985 xj 700x but not the motor. I would love to but I'm already battling the carbs. Wish you had a video about the floats and measuring them.

[@Mezzmoengineering]

I'll be setting my carbby floats in the next few days. I'll post a video of the process very soon....

[@alfredvradenburg2689]

@@Mezzmoengineering that would be great. I'm excited to see it. I just ordered new needles, floats and gaskets. The only part I'm struggling with is the measuring. I dont want to mess it all up. :/ but been watching your maxim videos and man you go all out! Love em and keep it up.

[@clickireland1113]

Well worth supporting thanks. Perfect timing to get the video I'm replacing the lower crankcase tomorrow. (I think).

[@Mezzmoengineering]

Good one, glad its been helpful

[@clickireland1113]

Hope the public takes my hint there. Q: Can I ask what solution do you add to the water for carb cleaning ultrasomic. Alkaline or acidic or PH neutral stuff? Thanks, When you get a minute cheers

[@Mezzmoengineering]

@@clickireland1113 Good question, Given I used bi carb soda to clean my carbs I just used straight water in the ultrasonic cleaner with the main aim to dissolve the soda. Someone else should be able to advise, I think the solution might differ on what you're trying to cleaning. A mild detergent would work well imo.

[@clickireland1113]

@@Mezzmoengineering Ah cheers for the reply. I'd reckon water'd be grand. I've all the bi carb soda grabbed off the shops shelf anyways. Waiting on kit from UK

[@clickireland1113]

@@Mezzmoengineering nrp-carbs.co.uk/shop/index.php?route=product/product&product_id=247&search=xj650 Seems good value if you ever need em.

[@ricardomoreno7279]

Una pregunta amigo ese motor es igual al de Yamaha radian yx600 1986 es el mismo

[@FoundingStockNZ]

Great videos mate, really appreciate the effort, thanks.

[@Mezzmoengineering]

Glad you like them!

[@thomashall6888]

Great job on the video! I'm subscribed.

[@Mezzmoengineering]

Thanks mate. Getting close to finishing my workshop so will be getting into some builds soon

[@AbR1e0]

Hello. I ordered the root liners from Yamaha diversion 900. They are completely identical to the Yamaha xj 650 root liners.

[@Mezzmoengineering]

Interesting, thanks for the info

[@aarongood5496]

Awesome!! I just unseized my 1981 yamaha xj650 maxim, but I'm not rebuilding it.

[@JoeRocket-sf6qs]

Great vid.very similar to the radian 600 and the 750 maxim.

[@Mezzmoengineering]

Thanks mate

[@jimmyguenza3767]

Looking good man !

[@davidgaunt9032]

Can you advise how you got the magneto flywheel off, I’m having heaps of problems removing mine.

[@Mezzmoengineering]

Hi mate. Buy yourself a bolt thats 16mm X 1.5mm pitch thread with at lease 50mm of thread. Once you remove the centre bolt you will see another thread inside there for this 16mm bolt. Insert a metal rod around 8mm diameter into the hole so it pushes on the end inside the hole, then screw in the 16mm bolt and it will come right off. The inner rod needs to be around 40 to 50mm long. Let me know how you go...

[@jakebane9450]

Love the video, super informative. I've got an '82 XJ650 myself as a project. I have two questions that i'm hoping you can answer or help me with. 1. Where do you get all your parts, especially engine parts like seals and gaskets? I'm having real trouble finding places that still stock parts. 2. I tried cranking the engine by hand to make sure it wasn't seized and I can only get about 1/2 turn before it stops and wont turn any further. Can't see anything under rocker cover so it looks like i'm going to have to take the cylinder head off to inspect the valves. Should i be replacing the gasket/o rings after that? Can you think of any reason that I wouldn't be able to crank the engine all the way other a piston hitting a valve? Any help would be greatly appreciated!

[@Mezzmoengineering]

Hi Jake, parts are hard to find. I got a few bits from private sellers on ebay as well as some new gear directly from Yamaha. Your Yamaha dealer should be able to get most of the seals and gaskets. The engine not turning could be a number of things. First to turn it by hand you should remove the spark plugs so there's no compression. If its still hard to turn it could be timing way out or possibly something gone wrong in the transmission. If you cant turn by hand with its plugs out then its probably best to pull it down to check the problem. Take cam cover off first to check inside there, eg timing marks. Then you could remove the sump to see what's there and if any loose bit are there which could indicate a damaged primary chain guide...

[@karlvanboxel561]

Beaut job man in the process of rebuilding my fz 750 engine which shares a similar bottom end architecture with the xj six gears and no shaft what’s that beaut engine paint you’ve used mint

[@Mezzmoengineering]

Thanks Karl. The cam cover paint is VHT Wrinkle black and the rest of the engine is Knight Rust guard is matt black

[@hunterandrus3320]

What an overhaul wow

[@Mezzmoengineering]

Thanks mate

[@paweszelest4061]

Mam taką YAMAYA 550 Maxima poczebuje zrobić taką naprawę silnika.

[@koma4953]

Hi @Mezzmoengineering I like what you done here ... amazing peace of work. Can you pls share what lube did you use for bearings inside motor? (purple one) Thank you

[@Mezzmoengineering]

Hi mate, sure, its Royal Purple Assembly lube. Its a great product...

[@stevec-b6214]

i noticed you stressed that the sealed bearing at 7:27 faces outwards, is that emphasis because the h...nes manual states the opposite way? just gladI am following YOUR video!

[@Mezzmoengineering]

Hi Mate, I haven't read that detail in the Haynes manual but yeah it needs to face out because the vacuum is pulling those lips tighter and sealing more. The other way around and air will pass

[@stevec-b6214]

@@Mezzmoengineering that makes sense - thanks - I have had enough of air passing lately...one other thing - the oil pump chain looks a bit slack? moves in/out mebbe 15mm, it doesnt lift off the sprocket tho - more paypalcoming - you have been SO much help, my build had stalled badly

[@Mezzmoengineering]

@@stevec-b6214 The oil pump chain doesn't have much slack in it, just a tiny bit. No chance of it lifting, if yours is too loose I'd recommend replacing it.

[@mandrakemalloy]

I also have this question. I'm rebuilding my 750 Seca and the UK Haynes manual states clearly the sealed side goes toward the inner edge. However my disassembly pics have it facing outward as you do. I guess I'm gonna go with how it was. Always a bit exciting ignoring an explicit instruction in the manual. Also thanks a bunch for this series, it's great!

[@Chechenzko]

Great job!

[@Mezzmoengineering]

Thanks!

[@yurisulca8633]

Hola dónde compraste los retenes y otros accesorios q se necesita para hacer el mantenimiento de esa parte del motor. Espero su pronta respuesta. Gracias

[@Mezzmoengineering]

Hi, I purchased the seals from eBay and some from my local Yamaha dealer. Not everything is still available but I just searched online until I found what I needed

[@SMAAirAssault]

Need a full parts list please!

[@Mezzmoengineering]

Hi mate, check this site, www.cmsnl.com/yamaha-xj650_model16829/?gclid=EAIaIQobChMI9-bz0YHMgAMVPdkWBR0p-QRnEAAYASAAEgIue_D_BwE You can make your list from there.

[@GR3TSCH3]

Hey Mezzmo, Just 1 question about the Sealing ring in the Final drive at 6:25. There is no one in mine. So what to do? Sorry for the bad english. :)

[@Mezzmoengineering]

HI Mate, you need at least one half ring for each of the bearings. As long as there is one per bearing it will be ok. This half ring can site on either the top or lower case half. But you will have problems if there is no half rings at all on each bearing

[@jimjones8300]

Need a full video of a 84 xj 700 max x

[@josephkirchhoff3493]

Hey dude, I'm engaged in the same undertaking. I'm having trouble aligning the timing points with the cams. When I spin the crank to E, the midway point, the cams do not want to sit in their appropriate positions, therefore I am unable to determine when the crank is halfway.

[@Mezzmoengineering]

Hi mate, if you have the head off and the cams are out then you can bolt it on with the crank in any position. Once the head is on, turn the crank to TDC and then install the cams with the marks pointing upwards like in my video. With cams in, install chain, rotate to check timing is correct and you should be good to go. Hope this helps.

[@josephkirchhoff3493]

@@Mezzmoengineering Thanks! Just figured it out!

[@kaedonnaylor979]

Where do you get your parts?!

[@Mezzmoengineering]

Hi mate, just a lot of searching online. Ebay etc as well as getting some basic things from Yamaha. Things like emblems and side covers were very hard to find, expensive but possible to find if you take the time.

[@kaedonnaylor979]

Thank you

[@plexiglass4930]

Well done!!

[@Mezzmoengineering]

Thanks mate

[@petjaleino1042]

Is there an o-ring around every pin/dovel between the cases?

[@Mezzmoengineering]

Hi Mate, no, not all pins have the o-ring. The main o-ring is to seal the oil gallery as per video

[@petjaleino1042]

Ok. Just thought that I saw that there is o- rings in the 3 pins in the lower casing. Thank you 4 the answer.

[@Mezzmoengineering]

Hi again, the main o-ring is where I show in the video from the oil gallery. There are others but from memory I don’t think they are on every pin. They are where the oil feeds are. One of these feeds is for the cams. Best way to see is closely check all the pins to see if there’s a small space machined in the casing. If there’s a small chamfer then it needs an o-ring, if it’s machine completely square then there will be no O-ring. Hope this helps

[@pethelprc4721]

i waited though this whole video just in hopes to see the cam chain tensioner broken down so i could see the tensioner bolt then you use the 750 auto tensioner....lol maybe you can answer question for me, while the engine is still in the bike fully assembled can the tensioner bolt be simply pulled and replaced without causing problems???

[@Mezzmoengineering]

Hi mate, Sure. All you need to do is buy a XJ750 tensioner, remove the centre bolt so you can push the pin right back. Bolt to barrels first, then install spring and tighten nut. Like I did in the video and it will self adjust. The old one can just be taken out and swap straight over. The main thing is installing the new one with the pin pushed in and you can only do that with the bolt and spring removed.

[@revivemotorcycles]

Hi Mate, Can I remove head and cylinders with engine in frame? I bought a bike with head and cylinders out I'm wondering if even possible to reinstall new heads etc with engine in

[@Mezzmoengineering]

Good question, I’m not sure as I haven’t tried. My guess is I don’t think there’s enough room. Even if it’s possible, I think the lack of space would make it easier to just remove the engine so you have full access.

[@ChicoDelmar-x1f]

Trying to rebuild my 81 midnight max Any advice? Either then tossing it away? Thanks 🙏 for the videos

[@Mezzmoengineering]

Sounds like a good plan. Only advice is take your time, use good parts and use videos like mine to help you with info you need

[@TheVictorFour]

Do you have video showing removing of the gear selector cover?

[@Mezzmoengineering]

Hi mate, no but its just reverse of the assembly shown in this video. Once you remove the levers and bolts it will slide off.

[@TheVictorFour]

@@Mezzmoengineering I used to despatch XJ650s many years ago. All of them got stuck in first gear, all of them had a bit of guide brown off and sit on gear sen;ector drum and we managed to get them out just through inspection video. Just had exactly same happen with my turbo. I'm assuming its primary drive chain. Now specking full engine strip to get to this one bit that Yamaha must have know fails!

[@Mezzmoengineering]

@@TheVictorFour Yep, the chain guide is a known fault. In fact, I noticed Yamaha had redesigned the replacement one I purchased directly through them. Original has 3 bolts and new version uses only 2 bolts.

[@TheVictorFour]

@@Mezzmoengineering did you get any of your parts from xj4ever in the states?

[@pantherzzz111]

Hi again, thanks for your reply, very decent of you. In your video part 25, 2 minutes 31 seconds in, you are fitting a guide in the upper crank case, the bearing in question you have installed just to the left. Can I ask where you got the big bore kit from, have you any experience with over size pistons kits from cruzin image. Many thanks mate, I do appreciate it, cheers.

[@Mezzmoengineering]

Hi mate, OK I see the bearing. Yes, you need a blind puller for that one. I left it in as it was in very good condition. I got the big bore kit from a private seller. Not sure who sells them now. I haven't had any experience with other motorbike big bore kits. I have done a big bore on my celica too but used Wiseco pistons. Without knowing the brand I'd suggest searching for reviews. Most pistons are fine. If your concerned you can balance them, check my early video on engine balancing on my celica build from around 5 years ago as it shows exactly how to do it.

[@stevec-b6214]

Maestro! you have helped my build enormously. Did you put new parts in the starter clutch? XJ forum seems to hint it can cause probs. I have the opportunity because the bike jammed in second gear on my test ride, and the motor is on the bench again. When I split the cases the lower casing gear shaft was solid. I couldn`t get the selector fork shaft out, as the fork that sits in 5th gear was jammed, I had to tap the bearing out from the inside with a thin drift, I just can`t figure what went wrong

[@Mezzmoengineering]

Hi mate, glad my video has been helpful. I left the start clutch as it was because it was still like new, All damaged or worn parts were replaced. Good luck with your build.

[@cristiandelacruz4072]

amigo podrias indicarme donde compraste todos los repuestos que utilizaste en este proyecto de este motor }

[@ArnoldSwarc]

hi, wind blew down my same model motorcycle on it side oil petrol and baterry fluid leaked out. But i still have same level of oil and cant seem to find spot where it leaked out could u advice? and is there a chance that oil will stay and hidrolock engine?

[@Mezzmoengineering]

Oil might be from your rear wheel drive unit...Engine won't lock due to oil as it can't get past the piston rings. Locking will be if fuel gets through carbs into top compression area.

[@tameshiah5012]

Where did you find that police alternator cover pretty bad ass? I would like to have one for myself.

[@Mezzmoengineering]

@@tameshiah5012 Hi, I purchased a complete XJ750P police bike. I used the crank, cover, fuel tank and some other parts to build this into an 820cc. Check my earlier video of the police bike. The police bike also has different carby jets and needle

[@AbR1e0]

Hello. Where I bought the main crankshaft bearings. 4h7-11416-11-00

[@Mezzmoengineering]

Hi, I had 3 engines that I used for parts. In the end I made a good condition full set of crank bearings so I didn't buy any. I think these are difficult to find now...

[@AbR1e0]

@@Mezzmoengineering Hello. Difficult is the wrong word, impossible to find at all. One question, an pick up from another motorcycle. For example YAMAHA XJ 600 (49A-11656-10-00 ) or make to order.

[@Mezzmoengineering]

@@AbR1e0 Thanks what I did, used bearings from another engine. I think that's your best option....

[@kevinmayes9072]

O rings on crankcase mating dowel pins (one visible 10.48 top left) Hi Mezzmo, do I see O rings on the crankcase mating dowel pins ? (One visible top left frame 10.48). I can't find any reference or part numbers for these anywhere. Awesome video by the way.

[@Mezzmoengineering]

Hi Kevin, check this link. It has the info you need....www.cmsnl.com/yamaha-xj750r-seca-1982-c-usa_model8879/partslist/B-08.html#.ZDnTY3ZBy5c

[@kevinmayes9072]

@@Mezzmoengineering , really good of you to take the trouble to reply and upload the link, thanks. I see every O ring including the one by the clutch shaft bearing with the machined recess but nothing for the other three crankcase halve locating dowels. Looks like I'll be rolling the dice on this one.

[@Mezzmoengineering]

@@kevinmayes9072 Hi mate, the other dowel you refer too don't have an o-ring as they just locate the cases. Only sealant around them. The one for the o-ring is there because its the oil feed gallery.

[@TheSteveniell]

Awesome. I love your videos. I just hope I’d be a little bit more knowledgeable so I can advance on this project I got myself into with almost no experience just the love for the bikes. Like right now I would like to know if oil is pumping on my Yamaha 1981 XJ650 Maxim but can’t find answers on the internet just how to chasing oil and so on.

[@Mezzmoengineering]

Thanks mate, good to hear you are tackling your project. Take a look at my "First start" video and you will see the line I remove to check oil is pumping. It's just before I start it up for the first time....

[@TheSteveniell]

@@Mezzmoengineering I’ll do it today and will give you a feed back. Thanks for your quick response. I really appreciate it. Keep it 🆙😎

[@TheSteveniell]

Sooo, today I just finished rebuilding my the carbs and cleaning the wires since I built a center box for hiding battery and extra wires. But when I started it started leaking a lot of oil from the oils filter plate. 🤦🏻‍♂️🙆🏻‍♂️ never ending built I call it. Aka What now!

[@TheSteveniell]

Now going back to your playlist and find the answers to my new problem. You are my inspiration. 💪😎

[@matthewryan3640]

Hey Mezzmo!..Thanks for a great Vid. I'm currently working on a 1986 XJ700N and I'm noticing a rattle also right behind the Gen. Is that what you heard before you broke it down?

[@Mezzmoengineering]

Yep that’s what I had which was the primary chain

[@moto-tec2377]

Do you know the torque spec for the bolts that hold the crank?

[@Mezzmoengineering]

Hi Chris, crank casing is 17.5ft/lb and rod ends is 14.5ft/lb. The sequence for the casing is marked on the casing itself.

[@carloschuckquinones5088]

Just have a question I have an 83XJ650 I'm having a hard time finding like little nuts and bolts that didn't come with the bike when I purchased it from the owner it was kind of already in pieces where do you order the your stuff from any little bit helps thanks

[@Mezzmoengineering]

Hi, I got some parts direct from my local Yamaha dealer including gaskets, seals, bolts etc. Some on ebay and some from other online sources. Check this link, www.cmsnl.com/yamaha-xj650_model16829/ it will help you find the part number of what you need and makes it much easier to find things.

[@christopherblair3667]

Man, where on Earth did you find those pistons and rings? I can't seem to find a set anywhere.

[@Mezzmoengineering]

Hi mate, I think I just got lucky. I haven't found anymore since either....

[@JBroezel]

Super nice job!!! (As always:-)

[@JoséRamónMendezRangel]

Me gusta mucho

[@willpalmer9908]

Hey mate- love your work!! I'm in Australia as well and fixing up an '81 XJ550 and curious about the ins and outs of subframe modifications. How was the process of getting it checked off for rego? Did you register it before modifying it? Also love the paint work on the engine! Would love to know the details of what was used and where you got it done. Cheers!

[@Mezzmoengineering]

Hi Will, glad you like it. I did everything myself, the whole build is on this channel. Bike was already registered, it was only a very minor change, not sure if they would technically deem that to be a mod as it didn't reduce frame strength in any way.

[@willpalmer9908]

@@Mezzmoengineering Good to know. Thanks for the quick response!

[@takhstakhs3610]

Hi my friend how ignition coil orders?

[@Mezzmoengineering]

Hi mate, one coil feeds cylinder 1 and 4, second coil goes to 2 and 3. It’s wasted spark so firing order is 1-2-4-3

[@bennyhill3642]

Im gunna go look an 82 xj750 Would you say finding oem parts pretty easy?

[@Mezzmoengineering]

Hi mate, no, findings parts wasn't easy. Depends what it is, general parts like seals etc are fairly easy but things like emblems, handle bars, side covers etc are very hard to find these days. Just takes time to search

[@amoahrahman6161]

Please i need help! Can i mount the cylinder head of yamaha 900 maxim on yamaha 650 maxim crankcase?

[@Mezzmoengineering]

Hi, I'm not sure as I haven't tried that. The 750 head will fit and then rebore its getting close to a 900 anyway.

[@stevec-b6214]

backlash - is that thou mm? the gauges on ebay just do 0.01 thats hundredths? lost my oil nozzle - 40 euros!

[@Mezzmoengineering]

Hi Mate, inches or imperial are measured in thousands and metric is measured in hundredths. I think you will find the ebay ones might be just metric which is fine. If imperial it needs to be in thousands. Mine have both markings, Eg in the video you see 0.011 thousands of an inch, which is 0.279mm. The backlash needs to be between 0.004 - 0.008 inches or 0.1-0.2mm. There are 40 thousands of an inch to every millimetre. So measuring hundredths of mm's is actually more accurate than thousands of an inch.

[@stevec-b6214]

@@Mezzmoengineering thanks mate - but actions speak louder so I sent you some cash!

[@Mezzmoengineering]

@@stevec-b6214 Thanks, much appreciated

[@stevec-b6214]

@@Mezzmoengineering found my oil nozzle and lost 2 idle screws I think thers a pattern emerging.......thanks again for your hard work, my rebuild is more basic - as clint eastwood said - a mans gotta realise his limitations......

[@Mezzmoengineering]

@@stevec-b6214 Thanks mate, good luck with your build

[@pajipower1]

Hi Mezzmo!! can you please point me in the direction where you ordered all the parts for a top end rebuild kit?

[@Mezzmoengineering]

Hi Mate, parts are getting harder to find. Some gear I purchased from my Yamaha dealer and most from searching online, Eg Ebay, stores etc. Most parts I had to pay a premium for and most were not from Australia. A top end kit shouldn't be too hard to find on ebay.

[@TheJaspreetsbhatia]

Hello sir from which website have u ordered the parts

[@Mezzmoengineering]

Hi Mate, some parts I purchased from my local Yamaha dealer, others on Ebay and private sellers from around the world. Many things are no longer available but they can still be found with private sales. Only challenge is rare items are costly....

[@TheJaspreetsbhatia]

@@Mezzmoengineering cheers mate your vedios are really helpful for me .. iam stuck with upper guide iam not finding it anyware would you care to help a bit .

[@jeromeygreen4788]

I can't for the life of me get the cylinders down over the pistons. Somehow one ring keeps bending.

[@Mezzmoengineering]

That’s odd. Do you have the correct rings? The chamfer on the base of the cylinder bores should guide them in. Also make sure you have a good voting of oil in the bore as well as the piston and rings. A gentle tap of the cylinder also helps things along

[@jeromeygreen4788]

@@Mezzmoengineering yeah, the rings measure in spec when level in the cylinders. They have the right gap measurement. I have a new set coming because I bent I bent the new ones and the leftover ones I saved that measured okay. Maybe I'm trying to go too quickly, I'll try to slow down but man, I almost think I need someone who knows what they are doing to look at me and just let me know the thing I'm clearly doing wrong.

[@rodslogic4350]

She looks sweet as 👍 BTW Great start to the video cheers.

[@ricardomoreno7279]

Cómo puedo conseguir todas esas partes

[@Mezzmoengineering]

Hi mate, parts are hard to find but I found what I needed either on eBay or other private sales online. Some things are very expensive but there is little choice if you need things that Yamaha no longer has

[@ricardomoreno7279]

@@Mezzmoengineering muchas gracias

[@ruelngatia5967]

Nice work.. Do the xj550 oil pump cover fit with the xj650 one?

[@Mezzmoengineering]

Hi Mate, I'm not sure as I've not worked on a 550. The 650 and 750 are interchangable

[@diegoaespitia]

did you order everything completely new, like the bearings, bolts, gaskets, seals? cause it looks like none of those are rusted up

[@Mezzmoengineering]

Hi, Yes all new gaskets and seals. Some bearings and some bolts. Some gear I just cleaned up and reused

[@meskutunas]

Can you write down valve cover gasket number? I can't find original one with the side plugs it's only aftermarket thin one :/ thanks

[@Mezzmoengineering]

Hi Mate, number is 5G21119300

[@christiaanpistorius5192]

Good day. I'm from South Africa. Just want to know if the xj900 engine rebuild would be the same as the xj650. Love the videos mate.

[@Mezzmoengineering]

Hi, I haven't done an XJ900 but I think it will be very similar to the 650

[@christiaanpistorius5192]

@@Mezzmoengineering thanks mate

[@vasyakas2392]

какие нужно поставить зазоры на клапанах?What are the valve clearances?

[@Mezzmoengineering]

Inlet is 0.004-0.006 and exhaust is 0.006-0.008 thousands of inch

[@vasyakas2392]

@@Mezzmoengineering thank you

[@vasyakas2392]

@@Mezzmoengineering I admire your hard work!

[@mariusdavel6900]

I have one question, can you tell us from what supplier you ordered the genuine Yamaha parts? Especially the orings, chain tensioner and piston rings? Thnak you!

[@Mezzmoengineering]

Hi Mate, The O-rings, some gaskets ans seals were direct from my local Yamaha dealer. Some were in Australia and others had to be shipped from Japan. Yamaha still has quite a few spares for this engine. The cam chain I purchased new online, again some things I found on ebay and other sources. You should be able to find what you need by searching online

[@euniceperez4510]

Is this all pretty much the same on 82 xj1100? Also spot on video. 👍

[@Mezzmoengineering]

I'm not familiar with the XJ100 but my guess is it will be very similar

[@euniceperez4510]

@@Mezzmoengineering thank you for the great vids, and the info.Got this motorcycle for 75$ at a garage sale. Will talk more later down the line when I got more of the bike disassembled. ✌

[@Mezzmoengineering]

@@euniceperez4510 Looks like a great project

[@silversanign9288]

If this engine same as xj750 seca?

[@Mezzmoengineering]

Hi Mate, XJ650 and XJ750 engines are almost the same. They have the same mounts minor differences in carby jet sizes, 750 has bigger pistons and crank. Cam profiles different but many parts interchange between these engines.

[@silversanign9288]

@@Mezzmoengineering tq for information just want to know about engine interior .So thank for video good for my reference.👍

[@Mezzmoengineering]

@@silversanign9288 All engine interior is the same except for crank, conrods and pistons.

[@silversanign9288]

@@Mezzmoengineering ok ..I will comment if anything happen .just need rebuild bike again so can take long trip.👍 btw if really important to buy manual?

[@Mezzmoengineering]

@@silversanign9288 Hi mate, if you are good mechanically then you don't really need a manual. Having said that, they are pretty cheap so its nice to have as it has all the specs in there

[@loganlogan732]

What are the torque specs for the connecting rods

[@Mezzmoengineering]

18.1ft/lb

[@loganlogan732]

Also does it matter what way the piston rings are facing when Installing the pistons

[@Mezzmoengineering]

@@loganlogan732 Yes it matters, there should be a mark on the rings showing which way faces up and the gaps of each ring need to be located in different spots. Info on this is easy to find using google.

[@clerk02-velosojohnmichael64]

How much did it cost you?

[@Mezzmoengineering]

The complete engine build, including all OEM new covers, gaskets, pistons, new head etc etc was just over $2000AUD. All work done myself. About $500 went on just the two brand new OEM crankcase side covers. Could be done cheaper but I went all in with as much OEM as I could find.

[@vasyakas2392]

Мото брат!подскажи пожалуйста,гильзы менять возможно на цылиндре? Yamaha xj 650. Не могу найти поршни второго ремонта(63.25) по этой причине думаю гильзы заменить.Moto brother! Tell me please, is it possible to change the liners on the cylinder? Yamaha xj 650. I can not find the pistons of the second repair (63.25) for this reason I think the liners should be replaced.

[@Mezzmoengineering]

Hi, I'm not sure if the liners can be replaced. A machine shop could do that for you though. I think your best bet is to keep searching for oversize pistons or just buy another cylinder housing

[@maniek23lata]

Dzięki za filmik pozdrawiam

[@iacevedo87]

This is awesome! I’m working on the same engine and this is a god send! So it’s a 650 crankcase and a 750 crank. The cylinder jug is a xj750 or 650?

[@Mezzmoengineering]

Yep, XJ650 crankcasing, XJ750 crank and rods and oversized pistons. 650 head is the same as 750 but cams are different so I have 750 cams and also a carby jet upgrade. Check my other videos...

[@corncobbbhunting7082]

How much did this engine overhaul cost you for parts?

[@Mezzmoengineering]

Hi, I haven’t added it up but guessing around $2K. The most expensive parts were the new side covers.

[@clickireland1113]

Just at the pre engine build stage. If you wanna see the bike before I started I just put a walk round video up. "Yamaha XJ650 ditch bike" There wont be an oscar anytime soon.

[@Mezzmoengineering]

I'll check it out, good luck with your build

[@clickireland1113]

@@Mezzmoengineering Thanks it'll all work out. I'll put up videos of the parts soon Will let ya know

[@jerryking1434]

@@clickireland1113 hows your progress ..???

[@elioalexanderlabradorduque799]

Te faltó los torque de todo lo tornillos y tuercas consu repetido orden y fuerza las tolerancias entre puntas de los anillo y la tolerancias en las ranuras de los pistones

[@Mezzmoengineering]

Hi mate, not sure what you mean? I torqued all bolts to spec and in the correct order. All piston ring gaps were checked and set. The ring height clearance was already ok as it came as a set

[@tomek860]

This shit should be on netlix

[@Mezzmoengineering]

Thanks mate

[@neilyakuza6595]

Please, rebuild mine. 😁

[@ทักษิณปัญญาเพียง]

สวัสดี ครับ 😍😍😍

[@valneisantoscostacosta5645]

O motor dela ficou zerado 😊🙌👍

[@hansasal9501]

Warum schmiert er denn die Dichtpampe auf die Lagerböcke neben den Hauptlagern? Da läuft er doch Gefahr, das sich die Scheiße in die Lager drückt. Hauptsache draufgeschmiert. Viel hilft viel

[@Mezzmoengineering]

Hi, not sure the part you mean. If you mean the crank end seals on the outside, then that was sealant and not grease. I do that to ensure there is no leak.

[@cavscout62]

All was good until the “techno” NOISE started. Damn.