1982 XJ650 Maxim Build

what is dipping?
"Fished up dipping the lower forks."

and what do you do with the fish after?

 

Plasti-dip

 

Fish and dips!

 

Got the bottom of the front fender de-rusted and painted.

IMG_1504 by Justin Schwab, on Flickr

Attempted to source new sliver emblems and couldn't find any that fit worth a crap so I decided to re-finish the 1 good stock one I had, turned out pretty good. Also got a OEM emblem for the other side on order from chacal tht will get the same treatment.

Painted all bright silver then taped off the letters and sprayed the background black.

IMG_1505 by Justin Schwab, on Flickr

IMG_1508 by Justin Schwab, on Flickr

Also ordered some Emgo superbike bars and have a request into chacal for the rest of the parts needed to do the swap.

 

Nice! Love that you went from "got this old bike, not sure I want to mess with it" to "lets get it back on the road in perfect mechanical shape and enjoy it!" I have the same bike and I can say you're really going to enjoy riding it. I've owned and still have a couple other 4 cyl UJM and the maxim is my favorite.

 

So when I was putting my exhaust on I noticed the previous oil leak on the front of the motor. I'm hoping that this was from the valve cover gasket and not the head gasket. What do you think?

I plan on using some de-greaser and cleaning it up once I get the bike back together and I can roll it outside where I can clean it. Then running a while and see if more oil appears. I replaced the valve cover gasket when I adjusted the clearances.

IMG_1510 by Justin Schwab, on Flickr

IMG_1511 by Justin Schwab, on Flickr

IMG_1512 by Justin Schwab, on Flickr

 

Polished up the front wheel and got the new rotor installed.

 

Leak: looks like the valve cover gasket to me. You plan for confirmation is solid. Dust the cleaned area with talc so you can pinpoint any leaks quickly.

 

Got more work done this evening thanks to care package from XJ4ever.

New bars are mounted,along with new MC, and brake lines.

IMG_1523 by Justin Schwab, on Flickr

IMG_1516 by Justin Schwab, on Flickr

IMG_1515 by Justin Schwab, on Flickr

IMG_1517 by Justin Schwab, on Flickr

Then I ran out of parts, waiting on the next package to arrive to finish the bars.

So I moved onto disassembling the rear.

IMG_1522 by Justin Schwab, on Flickr

1. Question about the rear as this is my first shaft drive bike. Can I remove the "rear differential" from the drive shaft just by taking out the 4 bolts?

2. Is there a gasket in there that should be replaced? It looks like grease is leaking out where the shaft meets the differential.

3. Also is there anything inside the differential that should be serviced like fluid change?

4. The rear bearing kit included 3 bearings but I believe that I only use 2 of them correct, the 3rd bearing is for a chain bike?

 

1. Yes. The drive shaft may, or may not, have a wir circlip that helps locate it in the rear u-joint socket. If yours has the circlip the driveshaft will likely stay connecte to the U-joint.

2. No gasket at that flange. There is an oil seal (several actually, and an o-ring) on the input side of the final drive that may be leaking, or you could have a leak at the output shaft seal on the engine, which would allow oil to run down into the swingarm tube.

3. Gear oil change would be wise. Otherwise nothing will be needed unless thre is a leaky oil seal, or signs of a bad bearing.

4. The rear wheel has three bearings. Two that stack on the drive-spline side, and one on the brake drum side.

If you have to service the final drive beyond a oil change, you will NEED to have a service manual on hand. There are things that you have to know, and do correctly, which go beyond what I think is reasonable to write up here (and waiting for answers when you have it apart sucks).

 

just a thought your handle bars are painted/coated, make sure that your starter ground has aplace to ground to.it should go back to the 6 pin connector and have a ground to mate to.

it looks like it does in the wiring diagram.


nice HD shirt in the mirror

 

Yeah the start button has a ground wire, it even works not on the bars, I verified it worked when I disassembled it to clean it, it works better now.

 

Still have quite a few of them, even though the HD is gone now.

 

When you replaced the valve cover, make sure to get all new donuts, too.

Also, the '82 should have the ground wire to the right control.......as yours does. The early ones did not

 

Yep, new doughnuts, pain to get installed but they are new.

 

they go on real easy with the little cone tool

 

I just push them on by hand. Warmed up in the sun, and a drop of oil-- they slide right on

 

@MattiThundrrr

 

Mmm. Donuts!

Wait, Dave did what to the donuts?

 

Warmed them in the sun and then put oil on them to make them slippery so he can push it with his hand. . . . .





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taking things out of context could make me a great politician or news reporter!