1982 XJ650J chopper project

This is a project that my sons and I started together. It's a 1982 Yamaha Maxim XJ650J. I'm trying to document it in pictures, so I might be able to help someone else with the courage to start on their own. I've been riding since I was 15, (41 now) and have *never* removed an engine block from a frame.. until now.. Thanks people at XJ Bikes.. I wouldn't have started without seeing you go first. So, here it is..
Enjoy!

 

The intake manifolds look a little rough.

 

more cracked intake manifolds

 

wheels and bars off.

 

wheel, back fender off

 

getting there

 

time to pull the carbs!

 

The carbs look pretty good inside, but they're *horrible* outside..
I'm gonna try the lemon juice bath I've read about for them.
Anyone ever try soaking their carbs in lemon juice? Does this actually work?

 

grungy carb hats

 

time to remove the { intake manifolds? | carb holders? | intake boots? }

Does ANYONE know what these are properly called?

ALSO- does anyone have access to a TourMax parts number list?
I can't seem to find one online.

 

swingarm off, harness off, headlight off, engine OUT!
I'm gonna leave the forks on for mock-up, and next comes the fun part.
Cutting, welding, grinding, sanding, priming, and painting.
suggestions? comments? This is our first bike build, so we're open.
Thanks!

 

Maxim-in-a-box?

 

More to come, we're busy with the carbs, wheels, and swingarm cleaning atm.

 

Welcome aboard! It is VERY refreshing to see someone come in to the forums, look around.......and say "I'm jumping right in and am not afraid to do so"! Yeah, you may be nervous, and have questions......that's GOOD! That's also why YOU're here, and why WE're here. You'll be fine, and you're gonna end up with a bike that you will be so incredibly proud of...........and so will we.

Again, glad you're here.

Hey, when you get to putting things back together, don't forget to check valve shim clearances and if you need to swap some out, let me know......I have a shim pool available.

Dave Fox

 

another member whose bike I somewhat expect to come across this summer in mn. starting off nicely!

 

Hi Dave,
We haven't cracked the block open yet, but thank you for the offer! I'm hoping that the inside of the engine looks as good as the carbs did on the inside, but I kinda doubt it.

 

Welcome Agree with Dave it's good to see someone getting stuck into it. How come you're stripping the engine though, is there a fault you know about?

Just wondering because generally if the compressions are good these motors are very, very tough & you may be throwing a lot of money into a sound unit when you could just set the valves up, add fresh oil/filter & run it.

Again welcome, I trust I don't need to warn you about brakes & tires but all the same please have a look at BigFitz's rear brake shoe failure thread, link is in my signature. Thanks

 

Just cleaning it up, mainly.. It's filthy.. It ran perfectly before I started breaking it down. I think the farthest I may go into the engine is replacing the valve cover gasket, and removing the starter to clean it/around it. The carbs are getting new float bowl gaskets, internals cleaned up, and new intake manifolds and gaskets. I've ordered new front and rear brake pads/shoes, and new tires front and rear. Fork seals are ordered, too. Thanks for the input guys.. Nice to not feel alone cutting up something already so cool..

 

Good stuff, yeah if it ran well before I'd suggest just replacing the valve cover gasket (and "donut" pressure-washers for the bolts too, they provide the clamping force for the cover not the actual tightness of the bolts) and checking/setting valve clearances while you're in there (it very often gets skipped as people think it's hard work with being shims, when it's simplicity itself).

Oh, and the good clean up you mentioned too!

 

Here they are all cleaned up.. Much better.. A little pitted, but they are 31 years old.. Amazing what Coca-Cola and crumpled up aluminum foil will do to rust on chrome.. Gonna have to run them over the buffing wheel once or twice..

 

Squeaky clean (almost)

 

Oil filter cover

 

oil filter cover inside

 

NICE!!!

skillet

 

Just found a NOS set of TourMax intake manifolds for my XJ *with gaskets* for $60.. SWEET!!!

 

Hey moveing along well nice your being pic happy as well but how much time u have in it so far? And what u thing ur month year end time might be? We all know your never done working on the bike but just wondering

 

Not much, since it won't stop snowing here.. Including tear-down, and rebuilding the carbs, and clean-up, I bet I've spent about 12 solid hours on it so far..
I'm hoping to be riding it by June or July.
I have another bike, so I honestly don't care if its ready or not.
It's not gonna hit the road until it's done.

 

Right now, I'm waiting for float bowl gaskets, and the new intake manifolds I bought. I'm gonna haul the block down to an auto shop this weekend that has a heated water pressure washer, and plug the intake and exhaust manifolds, and let er buck. 190 degree water should take off most of the grease and grime.. Then, it's valve cover gaskets, valve shim clearances, correcting the silly engineering on the rear of the frame, grinding, sanding, priming, painting, polishing, rubbing, re-assembly, and riding.
That last bit is my favorite part of the whole thing..

 

wow nice work thus far... carbs look amazing! you are definitely in over my head! haha!

 

Pulled the valve cover, looks pretty clean.

 

Cleaned up valve cover, needs paint.

 

Carbs are back together, and smooth as silk.. Can't WAIT to get the tube bender. Ordering it today!!

 

How much driveshaft angle is too much?

 

I think you really need the motor fitted to judge it, but I have heard of other members grinding the corners of a UJ that was catching slightly to allow a lower ride height... Can't recall who now, might have been either mad bohemian, barry george or crath... but don't take that as gospel...

 

No goin back now... WOOOHOOO!!!!

 

getting ready to hard-tail it..

 

My son just getting started with some extra support.

 

my son, fabricating the ends of the hardtail.

 

tacking things up.

 

tacking things up.

 

tacking things up.

 

Setting the stance. I think it's looking pretty good so far. We may be looking for shorter fork springs.
We're *still* waiting on the pipe bender.

 

Looks good so far , I too am in the process of a 82 XJ750J Bobber Project.

 

Nice work.

 

Thanks, guys. We've finished hard-tailing it, and we're taking our time trying to make everything smooth and clean. Here's what's left:
1. replace fork seals - got em.
2. prep and paint frame.
3. remove 3 broken manifold bolts. - yup.. dammit.
4. check/adjust valve shim clearance - hoping I can shuffle.
5. replace valve cover gasket and rubber pressure bushings -need to get.
6. replace brake shoes and pads - have em.
7. install handlebars - have em, but need brake/clutch/throttle cables.
8. clean/prep/paint engine block
9. tires/seat/fwd controls/harness/lights
10. fabricating something to hide the electronics, but still allow access.

what am I forgetting??

 

Just ran across this.. It was Crath.

 

Just about done with cleaning up the frame, we spent a little time knocking down some 31 year-old slag, and cleaning up some of the welds.

 

motor is back in the frame, hoping to have her running and riding around on Monday. (before we tear it down for the last time, and make it pretty)

 

Awesome job so far, this is a great thread. I like the approach yall are taking to this build. Say I think you mentioned you wanted to lower the front end with shorter springs? Have you though about just slipping the forks through the trees an inch or two?

 

nice job so far! looking forward to seeing more.....