XJ550 street fighter Project, "pic heavy"... Finally DONE!!!

Hi all, I'm new to the site but already have gotten a few ideas on customizing my 83' xj550, so I thought I would let you in on my project and progress.

Had this bike since 1995, it's been stored for the past 5-6 years, so I took it out of dads basement and started yet another project

the plan is to drop the front and raise the rear a bit, custom headlights and tail lights, chopped fenders, custom exhaust, and custom paint, anything else I think of as I go along... well here it goes

The Start Nov 28/2006:


the tear down:




cleaning and painting the motor and frame:





motor back in:


mocking up of the new headlights:

*OLD stock one:


new ones taped in place, signals are made into them, so soon saying goodbye to the stock indicators:



fabrication of the front headlight bezel Dec 02/2006:



lowered the front a bit and rasied the rear, rear seems a little too high, so I got some more tweeking to do:


Dec 26/2006
I've been searching for a certain set of drag bars, but could not find what I wanted so using the stockers I made my own :twisted:











Took the stock front fender and shortened it, also made it so it looks layered (stepped), once the body work is done should look pretty good (I hope :roll: )





Dec 31/2006
painted the front forks and gauges, say good bye to more chrome :twisted:





started the beautiful task of fiberglassing the front bezel and sanding and sanding and sanding... (still not done! :roll: )





I think it's going to look alright on the bike:


then after staring at the "banana" seat I got to cutting it up and mocking up the fiberglass mold, which means more sanding to come :wink: !!!!





please check back for more updates

 

Re: XJ550 Project bike, "pic heavy"

This thing is sweet.keep us posted please.

 

Re: XJ550 Project bike, "pic heavy"

What kind of paint are you using on the engine.And welcome to the site.

 

Re: XJ550 Project bike, "pic heavy"

very nice.....we need to talk, because Im trying to turn my bike into more of a streetfighter, and if i cant find some clues on where to start, I might have to go a different route...but looks like your on my page....

How did you do that seat, and does that sucker make you hug the gas tank? and are you going to keep that gas tank stock?

 

Re: XJ550 Project bike, "pic heavy"

engine is done with all high temp ceramic paint, from the primer to the color to the clear , engine was blasted and sanded well before the primer

 

Re: XJ550 Project bike, "pic heavy"

You've got a very interresting project going, good work.

 

Re: XJ550 Project bike, "pic heavy"

I started by wanting to lowering the front 1" and changing the huge 8" headlight to something I liked (first I had two 4" round lights mounted which looked great but liked what I have now a bit more), everything else just seems to follow. I have somewhat of a plan but alot of what is done and going to be done is "on the fly".

The seat is the stock one with the vinyl removed and the foam cut just to remove the rear section, theres no difference in the way I sit on it, but after the fiberglassing I have to do it will look totally different...and I'm keeping the stock tank but going to add some accent pieces and fill the emblem mounts, man I love my welder :lol:

 

Re: XJ550 Project bike, "pic heavy"

What do you plan on doing to the seat?I am curious cause I have a old gsxr(8) and want to make a newer style rear for it.

 

Re: XJ550 Project bike, "pic heavy"

going to recover the foam and fiberglass the rest, it will then be color matched (which I haven't decided on right yet) with the rest of the bike.

those gsxr's look great with an undertail, integrated signals in the brake light (no indicators), and a rear seat cowl (get rid of the back seat if you can)

 

Re: XJ550 Project bike, "pic heavy"

Too cool. Will be very interested to see it finished. Anything special going on with the rear lighting or maybe chassis lights?

 

Re: XJ550 Project bike, "pic heavy"

indicators and brake will be integrated led's and molded into the tool compartment door (if I can figure it out :roll: ), trying to design a rear fender that mounts to the swing arm that incorporates the license plate and marker light but we shall see
hopefully I should have my seat and front headlight bezel done by next week

 

Re: XJ550 Project bike, "pic heavy"

nice bike man, can't wait to see the finished product!

 

Re: XJ550 Project bike, "pic heavy"

I started at the seat tonight, heres some materials...good old duct tape!!!



foam used to get the shape I want, then used fleece to cover, all I got to do is crack the resin to it and let the sanding begin :roll:




then I covered the seat cushion in a material called ultra leather, is't leather, but more stretchy, softer and durable than vinyl, stuff sells for about $250 sq yrd, but the fabric shop I went to gave me enough to do plus some extra seat foam for $20 ( they had some ends left over from a job :lol: )


then the test fit...



I think it's gonna look great when the back gets fiberglassed, sanded and color matched to the rest of the bike

Still more to come! :twisted: ...

Jason

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

Looks to me like you may have solved that XJ seat pushing rider into the tank problem. How about some side shots of the seat on the bike.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

as requested...

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

So, I'm liking the red on the engine, what gave you the idea to do red?

BTW, all the mods are right on!

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

it's a candy red color, I painted my 87 f150 lowrider ( http://www.cardomain.com/ride/653921 ) with it a couple years ago and loved it, (you should see it in the sun, it's got a crazy metallic look to it) so I got some ceramic paint mixed for the engine, I think I'm going to paint the whole bike with that color, and do the same color scheme with my Bronco and bike trailer this summer. :wink:

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

Thanks.

Looks great. Looking forward to the ride report.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

cool i like it hope the best with the fglass keep us posted.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

Very nice. My plan for my rear lights was to incorporate them into the grab bar in the back. Might be worth a thought. I was going to box it in and then flush mount LED brake and turn signals. Some food for thought, but once again, excellent progress.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

never thought of that, that is a great idea, especially if you use those led strips

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

I'm putting pipes off an R6 on the bike, I aquired one a couple days ago so tonight to put the R6 exhaust pipe under the knife, heres some pics for your enjoyment...

heres the stocker


mounting brackets cut off and can marked for surgery:


I cut approx 8" off it:



a bit of modification to the inlet pipe:


and presto!!!:


now I just got to repeat the process on my second pipe, which I should have in a couple of days. Going to have two of these mounted, bike just didn't look right with one

Stay tuned still more to come...

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

Wicked..... I wish I had the gear to do those sort of mods...

Keep them pictures coming 8)

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

Once, again your mods are awsome. However, the engineer in me wants to come out and meantion that there is no free lunch. I am curious if you just picked the R6 because of pipe styling, or if there is a mechanical reason. While I can readily admit that your craftmanship and techniques are stunning, I am wondering if you have given any thought to back pressure, or any other mechanical workings of the bike? Let us in on your chain of thought.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 3/07

well first off I wanted some shorty pipes, similar to the ones on the v-max , then I thought about a 4 into one mac, then after seeing the price of that I thought about constructing my own 4 into 1 using a pipe off a sport bike ( I'm trying to do it on a budjet ) then I aquired the pipe you see above, (was off my buddies 2001 R6 and he gave it to me for free) ...breath... that's how I decided on the R6 pipes, plus you can get them second hand (hardly used) for pretty cheap, Then came (and still doing) the mods to make it fit and the rest you will have to see at a later date! :twisted:

As for back pressure, the baffles in the R6 are a little bigger than my stock pipes but if back pressure becomes a problem (after tweaking the carbs and possible rejet), then the baffles out of the stock pipe (which I removed from the old stockers and are in great shape), will fit down inside the R6 pipe. I'm going for look as well as function... But only time will tell...I'll keep you informed :wink:

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 7/07

well finally had some time so I started the mounting of the R6 pipe that I have (still waiting on the second) and the slight modification of the rear suspension. I had everything mocked into place, the r6 pipe was exactly where I wanted, and was just about weld when I decided to try the bike with some weight on it, (to see if the pipe hit off anything) and right off the bat the kickstand wouldn't fold up :evil: , it was hitting off the pipe so I had to go back to the drawing board :? ... anyway long story short I modified the stock crossover so the R6 pipe fits right into it and it fits better now than before...

so heres a sneek preview of what the bike is going to somewhat look like, its a little rough and the paint scheme is going to change but it should give you all some idea:



still got a ways to go though...


Jason

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 14/07

It's going to look mean when its done, keep up the play by play!

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 14/07

Well I finally got the rear suspension done and the second pipe modified, also got the exhaust done. All I need to make is a mount for the cans, and I got one of those midnight sunburns from my welder (that what I get for tack welding without my helmet :roll: )

heres the mod to the rear suspension, you can see in the second pic where the rear shock use to mount and where it will mount now, 7/8 inch raise. Doesn't seem much until you sit on the bike :



modification of the crossover... cut off the outlet tubes and welded on bigger ones at different angles to Accommodate the R6 pipes, also added some side plates for Aesthetics:




heres the pipes held in place until I can make a few mounts:




And heres how It sits as of now:

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 14/07

What part of Newfoundland are you in? I'm from Mt. Pearl originally.

Nice work on the bike. I am always amazed when I go home that the bikes on the road look pretty much the same as the ones we were riding back in the 80's. I saw a nice NS400 going for $1500 there one summer. Wish I had had a way to bring it back with me!

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 14/07

Thanks, got to do something to keep me busy in the winter months! :lol: I'm living in Mount Pearl now, but I'm from Wesleyville (in central)!

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

I'm just curious, what are you Headlights off of? They look familar but I figure out from where.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

they are just generic, aftermarket lights, just seen them one day at some automotive place and bought them, haven't been able to find another set like them since though.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

A small update...

rear fender shortened and shaped, still got some finish work to do on it as well as the front fender, tail lights will be molded into the rear compartment and will incorporate brake, park and signals.:


front fender, something a little different!:


heres the one pipe I got painted, I think it looks alot better Black! still got to do the other one...


and a progress poser shot :lol:


going to get all the mechanical things clued up before I get into the body and paint!!, ordering a set of dyna coils and new wires for starts... want/need to see what it runs and sounds like before I go any further!!!

Stay tuned

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

Did you use some sort of clear over hi-temp black on your header pipes or are they the original finish? Lookin' good, by the way. I like the red on the valve cover.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

Dude, you are old school and cool. I love everything your doing, I even checked out your F150 Lowrider, looks like you painted that thing outside, that is really cool.

Love your work, cant wait to see it done.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

wow, amazingly nice. I was suspect when you said R6 pipes, but it has really grown on me. I am simply restoring my 82....nothing custom here. Just trying to get it back into reliable status. Only has 5000 miles on the clock, but it needs some tuning which I am working on.

Good job and keep us posted.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

Thanks for the comments...

the pipes were chrome, but after alot of grinding, sanding and prep, they were hit with some ceramic high heat primer, then ceramic high heat flat black, then ceramic high heat clear, it's kinda got a satin finish, not real gloss, which is what I wanted

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

Just curious, are you leaving the front forks black?


Keep it up and you'll have yourself a really nice custom ride.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

yeah, they were polished but I'm trying to get rid of as much chrome as possible on the bike, just a bit on the motor, gas cap, side covers, rims (maybe)and a bit on the pipes! I'm lazy when it comes to detailing and don't want to have to polish all that chrome and aluminum that my bike had, just wash and go!! :wink:

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

what about the pipe from the exhaust crossover to the muffler? Are you leaving that polished, or do you pan on making that black as well? I like the polished look there.

 

Re: XJ550 Project bike, "pic heavy" Updated Jan 21/07

that's staying chrome, what you see is pretty well what I'm doing, the rest of the bike is going candy red , seat pan, tank, fenders, side covers (minus the chrome piece), headlight bezel. The foot peg mounts (triangle piece that the exhaust bracket and rear foot pegs bolt to) will be painted black as well as a small tank guard/accent piece that I'm in the process of designing .

today I got my new grips, brake and clutch levers (black of course :wink: ) and ordered my new dynacoils and wires, should have them this weekend so I can fire it up to see what the pipes sound like...

stay tuned :twisted:

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 07/07

Well ... I never paint bright alloy. I'm a "Sand-it-'til-it's-smooth ... then, polish-it" guy!

Take a peek at the fork tube in my gallery.

But, hey ... man!
Anybody who is puting that much soul into a project ... deserves words of encouragement and advice from those who have been to The Mount.

Don't rush anything. Wet sand your Primer with 400 followed by 600 wet; too. Wet sand the Color ... too. Then, Clear it ... and Buff the Clear.

Make all the gawkers want a bike like the one you got!

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 07/07

I polished my forks a few years back (along with other things), took alot of time and elbow grease , the results were great, but the polished forks don't match with the "look" I am going for with the bike now IMO but I could always change my mind , great tips on the paint prep by the way

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 07/07

man thatz lookin sweet. keep us posted as im dying to see the end project. nice job..

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 07/07

heres the new coils, wires and a few new parts:


I connected the coils and came to find the gas tank wouldn't fit so I had to make a few mounts to turn the coils 45 degrees, tight fit but it works:


...so after all friday night and most of today trying to get the bike fired up I finally managed to get it going (gas problem, couldn't get the carbs primed right)...it idled way too high but at least it runs :roll: :

http://www.youtube.com/watch?v=Bj--91v1NoA

then after much thinking, adjusting and swearing :lol: , I got the idle down but the carbs are still in need of cleaning and need to be synchronized...

http://www.youtube.com/watch?v=Hvhgq-hJfC4

now on to some electrical :?

for some reason the sound timing in the vids is off
:?

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 11/07

You work is awesome and your small video inspired me to make this one of my 900

http://www.youtube.com/watch?v=4A-_lKt0kUk

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 11/07

Right on Low,
I saw the videos, now the sound on my laptop makes it hard to really tell, but, I think it sounds like you have a sync problem and from the look of the left exhaust bank there may be some carb float issues!?
STILL SHE RAN!

IT"S ALIVE!!

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 11/07

see that's what she use to run like...sounds good...did your bike always have a blue frame?, I like it...

...and Hvnbnd, I believe your right, going to have to get the carbs cleaned and in sync, was talking to my father who had the carbs apart about two yrs ago and he said the jets and seats were in bad shape, pretty gummed up and gas was only flowing through 2 of the carbs at the time :roll: , so once all this snow we have here goes ( in about 2-3 months :x ) the bike is going to the shop for a tune up.

On the up side it runs and the new dynacoils and wires work great, the bike started in -16 degrees with no problem (after I managed to prime the carbs :wink: ) , I use to have trouble starting it in +16 degrees :twisted:

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 11/07

Low-1-5-0

You might want to consider doing the carb job yourself, check out the following link and you may find you can do it. Rick has a very good class here on how to clean your carbs.

As for putting them in Sync, You can make your own YICS Tool and do it yourself. Follow the links below for more info. All this info is on this site, what a wonderful life.

With what I have seen abou you, I think it would be a piece of cake.

Clean Your Own Carb's - The Whole 9 Yards - by: Rick Massey

YICS Tool

Homemade Manometer

 

Re: XJ550 Project bike, "pic heavy" Updated Feb 11/07

may try the carb thing myself, but then again I know the service manager at the yamaha dealer, and the kawi dealer, and someone at the honda dealer, shold only cost me peanuts :wink:

i'll have to see... :lol: