1982 XJ550 Maxim rebuild

I work at a used atv n sled shop, ive found especially with brakes its usually easier n chaper to get a good used then try to rebuild an effed up one, speaking from experience...

 

if they're good and they're used, somebody rebuilt them

 

The grease gun trick does work great. If you feel the time will be wasted working on them, just get functional used. Soaking it for a while and then the grease gun trick should get the puck out. Using copper brush to get all the crud off and then hitting it with some polish and a polishing wheel could do the trick. As long as the puck moves out seals should be the only thing you need to rebuild. Again, this is only if you want to take the time to try to save them.

 

I'll make a decision on a rebuild if the piston will even come out. I have to get a large grease gun instead of the pistol-grip I use for more force. If not, I'll have to try to find a deal on a used caliper. Are there any model crosses that fit so I'm not limiting myself with the engine size? It's a single caliper, single piston, so I would suspect possibly the 650 Maxim has the same caliper? Fork oil and seals came in. Guess I'll be working on stripping and repainting the bodies next. The tubes look great so nothing to do there.

 

If you use a parts lookup site like partzilla.com, you can look up the part number and then click on that to get the fitment. That way you are not guessing. Caliper works on these models:

Yamaha Motorcycle 1981 XJ550H FRONT BRAKE CALIPER XJ550H

Yamaha Motorcycle 1982 XJ550J FRONT BRAKE CALIPER XJ550J K

Yamaha Motorcycle 1983 XJ750RK Front Brake-Caliper

Yamaha Motorcycle 1982 XJ750RJ Front Brake-Caliper

Yamaha Motorcycle 1982 XV920J Front Brake-Caliper

Yamaha Motorcycle 1981 XJ750RH Front Brake-Caliper

 

+1 The 650 Maxim uses a very different brake caliper. You would not be happy if you bought one and tried to make it fit.

 

Mulitple torchings, smokin soaks with PB Blaster inside, a 2ft piece of 3/16" wall dom pipe, an old pair of locking pliers and a vise. The seals had glued themselves to the piston. Bore has been polished with steel wool and just got a coat of frame paint. Will order a piston rebuild kit.

 

i still like my steam

 

Way to stick with it!

 

Steam pot soak? It would have likely worked in this case since it wasn't rusted to the bore. No way to really tell and the chamber had rust soup in it, so I expected way worse.

 

I may be able to re-use the piston. The scarred sections are outside the bore stroke, just need to smooth them down and give the whole thing a polish. It's really not in that bad of shape.

 

Use Polock's method only if you do not like the ceiling in your shop.

 

actually you tighten the bleeder, add about a ounce of water in the banjo bolt hole and put a real bolt in it the put the whole thing on your wifes stove, set the burner to medium and get to a safe place. it's ok if you don't use the stove, anything that will boil the water you put in it.
stand back, it gets extremely violent. the trick is finding the piston

 

Yeah, I have had plenty of close calls with stress testing on the shop press. I like my contained explosions on the range so will leave the steam pistons to you and your perforated stoves.

 

Have you ever shot an anvil? Same idea, but without gunpowder.

 

No but I have had fun with Tannerite. The legal limit is 100lbs.

 

Those look great and ready for the new kit to be installed.

 

After measuring the seal depths and the piston, there are too many rust pits and scratches near the pressure seal. Looks like it'll be a complete rebuild. Was hoping to avoid, but at least it will all be new components and ready for a new reliable life.

 

Ya that in a pinch could be used IMHO. I am guessing the parks on the left of the pic are from the removal process? The puck from this side does not look too bad besides the long marks. She was being eaten good by Mother Nature. As many have stated, if you will be doing another one of these bikes, a large grease gun works great. I did my last set that way, better than using compressed air, a little safer too.