BK's Winter RestoMod Project - 82 XJ650 Seca

Perfect opportunity to make it a triple

Before anyone says anything; yes you can. There is a group of racers who have been modifying Honda 650cc engines to be triples so they can run in a 500cc class.

 

Eh. I have like, five months until riding season. I have the machine. It does an awesome job cleaning stuff up. I'm this deep into it, might as well do it professionally.

Sort of. Since I'm getting a set of set of used jugs, I was under the impression that I'd have to hone it out along with new rings so the rings can "set' inside the new cylinder?

As far as the TORX, I have a 3/8" and a 1/2" impact gun. I did notice they're peened in there. Is there a special protocol for putting them back in?

 

Post deleted.

 

@k-moe: I thought you were joking but that sounds interesting. I think we should help bk get this sorted so hopefully he can stop feeling the way he does about it.

Gary H.

 

A drill bit and impact to get them out. A torque wrench and a punch to put them back. I installed new ones.

Gary H.

 

I also installed new bearing retainer bolts. I double up; blue loctite, and peened the edge.

You will have to set the end-gap of the new rings, and do a light hone if the factory cross-hatch is gone. I just use a ball hine to break the glaze and get a new cross-hatch (assuming the cylinder walls measure in-spec.

And I'm dead-on serious about the triple. It would be down on power from stock, but it would still run great. Maybe I'll tackle that project one day if I find a suitable engine for cheap enough.

 

Your first line had me all confused. haha

mmk. I forget how they looked, but are the bolts themselves peened or this there a washer behind it that is peened? And I'm guessing Chacal sells replacement bolts?

I'll do locktite for sure.

Bearing retainer bolts. Which ones are you referring to?

The jugs I ordered will get a honing.

 

Very important to bag and tag during the tear down. As long as you keep up with everything we'll help you put it back together.

The heads of the bolts are peened. Yes, Chacal has these and the bearing housing bolts. The timing plate assembly will get removed. The procedure will not disturb the pointer. You'll need that impact gun tho.

Gary H.

 

The peened fasteners are for the middle-gear bearing retainer.

 

a air or electric gun isn't the same as one you hit with a hammer, you'll see

 

Right now its been loosening the bolts and leaving them in the respective holes at removal.

I have three impact guns; 3/8" air, 1/2" air, and 1/2" electric (this thing is a monster).

So drill the actual peened portion then impact it off? I have that right?

You lost me there.

 

Just got an email that the jugs should be here by Friday.

And, I'm going over the images of the head and I see this:


Perhaps my memory is failing me, but that red portion doesn't look familiar on my bike.

 

Now I have people messing with my head.

Someone write this:

after seeing this pic:


I'm still not sure if that rod has ever been replaced. I see zero evidence of this motor ever being split. How accurate is the above statement though?

 

Well I can look at that oil and tell you how much air was in the front tire when it happened. It happened on a Thursday by the way.

 

Alright. So you and I are on agreement there. My conclusion was water in the oil from sitting for awhile.

from the same person:

What a prick.

 

Texting the previous owner now. Showed him the pic of the broken sleeve. "That's what happens with used vehicle. Part it out."

 

So.

http://www.ebay.com/itm/1982-Yamaha...es-/291349242142?_trksid=p2141725.m3641.l6368

Hm.

 

On second thought your impacts might be too much. If you don't have a impact driver you can try a set up like this...

It worked for me. Why would you need a new case?

Gary H.

 

Correct. I mis-understood what you said.

Gary H.

 

I have a 3/8" air gun, 3/8" butterfly, and a 3/8" air ratchet I can use.

 

the thing about a hand impact driver is, part of the force of the hammer blow pushes the bit into the screw and part of it turns the screw. there's no chance of the bit slipping and ruining the screw.
phillips heads that slip even with the right driver are no problem with a impact driver
even if you don't use it here, maybe ask santa for one

 

An air impact driver does the same thing as a hand impact driver (not all powered drivers are impact drivers though). I used my air impact with no trouble at all; didn't even need to drill the peens out.

 

Welp. Its done. Got the case split. Bearing journals are damaged. Lots of metal in there. Motor is garbage. I suppose I could build another motor with the risk of that being damaged too. I guess I'll start parting the bike out. Was really looking forward to this too.

 

That thar is the YICS chamber and ports, used on YICS engines only. Won't work on a non-YICS engine (like a XJ650RJ Seca).

 

Awesome. So the part that was suggested doesn't even fit on my bike.

Welp. This isn't going anywhere. I'll throw the cams back on the head tomorrow. Try to sell that off. Dismantle the bike and clear an area in the basement for parts. I'll start a thread in the for sale section. Try to recoup some of my money. This will be a fun process.

This was an expensive, hard lesson taught by this guy:
https://www.facebook.com/robin.eifler.12?fref=nf

 

Keep a lookout for a complete engine that is still an option .
Alan

 

It does fit, but the YICS ports won't hook up to anything. Not a problem at all. IT would be a problem if you had a YICS engine and bought barrels from a non-YICS engine.

EDIT: forgot to mention that the ports would need to be blocked off, which is just a matter of tapping the holes and fitting setscrews with Loc-Tite to hold them in place. I know that is' no matter to BK, but someone will read this thread one day and might need to know.

 

Please post a pic of the innerds of the split case.

Gary H.

 

That was discussed on ADV Rider. There is general agreement over there that the cost to rebuild the bottom end is prohibitive, and I agree. The crank bearings are toast and there was strong signs of the oil pump and transmission having been contaminated with the filings. If it was mine I'd probably part it out too. Some things just aren't worth saving . If it were one of a handfull of remaining XJ650 Secas then it'd be worthwhile.

 

What he said.

I do have a video and pictures, but I'm headed out in a minute. Last night I kicked back and watched a movie with the Mrs. instead of shop time.

There are metal bits everywhere in the case. All the journals have gouges I can feel with my finger. In fact, I ran a finger through one of them, and it slit my finger like a paper cut. One of the intermediate shafts next to the mid gear, when spun you can hear the crunchiness of the metal.

Its done. Its over. Yea, I can try to find another 650 or 750 to swap it over. Try to cobble something together. Risk that motor isn't junk either. Instead I'm going to find a bike in the $2500 range that is fully functional. It was a gamble buying a bike to fix up. I lost. Parting the bike out is my only saving grace to recoup some of my funds.

 

+1. Sorry it didn't work out BK.

Gary H.

 

+1 , people here will be able to take parts off your hands , or help you find parts depends which way you go

 

Sorry you had such a crappy time, I was rooting for you. My first bike was a 650 Maxim, smaller gas tank, questionable styling, fairly crappy handling, but the engine never failed to put a smile on my face. If you still have the frame, you can put a 750 engine in it, as an old friend from Canada did on his 650 Maxim frame. I now have 2 900 Secas, and they address all the issues I had with the Maxim, and even a ride on a new FZ9 only made me appreciate how much I love these bikes. I still have an old article from Cycle World, Saving Old standards, about a refresh on a 650 Seca. Sorry your engine turned out to be such a bomb.

 

Meh. Oh well. I bought a brand new bike and have put 1,200 miles on it so far this year. The XJ has been parted out. I've got like 2/3 of it left. Its slowly trickling away. Lesson learned for sure.

 

Whadya get?

 

DR650

 

Fardarrigger!!!! Haven't seen you in forever! Good to see you again, my friend!

Dave Fox