Yamaha XJ700XN/XNC & XJ700XS/XSC 1985–1986 Service Manual Set (P/N LIT-11616-04-68)

The supplement must be used with the included base manual. It supplies the XS/XSC revisions, while the base manual provides the detailed service procedures.

PDF Bookmarks, Diagram Detail and Page Count

Navigation and legibility: PDF text search is not available. Embedded bookmarks cover both publications, although “Back to Index” points to a separate Main.pdf file. Small wire-color codes and component numbers in the circuit diagrams are readable when enlarged. Portions of PDF pp. 61, 128, 133 and 179 are unreadable, affecting engine disassembly, coolant filling, carburetor removal and final-gear assembly.

One printable, English-language, 296-page PDF contains the two publications listed above and one combined cover page, already included in the total.

Engine, Shaft-Drive and Electrical Service

These selected service topics show the main repair and diagnostic areas. Additional sections cover crankcase ventilation and throttle-cable maintenance.

• Engine overhaul: Step-by-step procedures for engine removal, five-valve cylinder-head disassembly, valve-guide and seat repair, piston inspection, crankshaft bearing selection and camshaft timing.

• Clutch and transmission: Wet-clutch disassembly and reassembly, transmission-shaft inspection, shift-cam and fork checks, and starter-clutch inspection.

• Carburetors and tune-up: Mikuni BS33 overhaul, float-height and fuel-level adjustment, carburetor synchronization, valve-pad selection and ignition-timing checks.

• Cooling system: Water-pump disassembly and seal installation, thermostat testing, radiator-cap inspection and cooling-system pressure tests.

• Brakes and chassis: Caliper and master-cylinder repair, brake bleeding, rear drum-brake service, front-fork rebuilds, steering-head adjustment and swingarm-bearing work.

• Shaft drive: Symptom diagnosis, middle-gear damper disassembly, final-drive service, shim selection, and gear-lash measurement and adjustment.

• Electrical diagnosis: Starting interlocks, charging and TCI ignition tests, starter-motor overhaul, lighting and fuel-warning circuits, with model-specific wiring diagrams.

Written primarily for Yamaha dealers and qualified mechanics, these manuals assume a working knowledge of motorcycle repair and access to the specified tools.

Valve Train and Internal Engine Work

The engine chapter covers crankcase separation and reassembly, with connecting-rod and main-bearing clearance checks, color-coded bearing selection and component-specific torque tables. Valve-pad selection charts and camshaft timing views support cylinder-head service.

Camshaft and clutch handling: Valve-pad replacement requires camshaft removal, and the cam-chain retention notes address the risk of losing the chain into the crankcase. The clutch reassembly cautions explain how misaligned oil-pump drive gear tabs can be damaged as the clutch boss nut is tightened.

Carburetor Adjustment and Cooling Checks

The carburetor section view identifies the main, pilot and starter circuits. Separate XN/XNC jet-needle specifications and California-canister inspection help distinguish the documented fuel-system configurations; fuel-level checks specify Fuel Level Gauge YM-01312.

Coolant-flow drawings show the relationship between the pump, cylinder head, thermostat and radiator. Servicing the pressurized cooling system and internal engine components requires appropriate mechanical proficiency and the manual’s safety precautions.

Shaft-Drive Diagnosis and Setup

The troubleshooting material distinguishes shaft-drive symptoms from wheel-bearing noise and engine or transmission behavior. Gear-lash measurement drawings separate readings taken with the measuring tool from actual backlash at the gear teeth.

Shim-selection calculations and dimensioned drawings for final-gear press tools support workshop preparation. The final-drive bearing-retainer instructions also identify its left-hand thread.

Electrical Fault Tracing and Supplement Revisions

The electrical charts provide a route from symptoms to circuit and component tests, helping mechanics investigate starting, charging and ignition faults before selecting replacement parts. The charging-system cautions explain how disconnecting the battery while the generator operates can damage the regulator/rectifier.

The XS/XSC supplement adds revised ignition-timing checks, location-specific camshaft-cap clearances and fuel-warning-light diagnosis. Its circuit diagram identifies the additional diode in the wiring harness.

Selected Camshaft Clearances and Piston-Ring Wear Limits

For XS/XSC camshaft inspection, the supplement specifies camshaft-to-cap clearance of 0.020–0.054 mm at EX1/EX4 and IN1/IN4, compared with 0.050–0.084 mm at EX2/EX3 and IN2/IN3. The cam-cap location drawing identifies these measuring positions.

For piston inspection, both publications list a 1.0 mm installed ring-end-gap service limit for the top and second rings, alongside separate standard assembly ranges.