Another 900

Got the bike home & it does run, after a fashion.
Comp test,dry..........1-85 2-115 3-120 4-120
Wet.........................1-170 2-230 3- 210 4-210

Valves: EX..............1-0.15 2-0.10 3-0.17 4-0.16

IN...............0.06 2-0.10 3-0.15 4-0.10

Ring job for sure.

 

Will this one be in a magazine? I'd think "Classic bike" would be interested.

 

Before pic' 22 11 2009

 

Hahahahah hooked

I have a basket case in my garage with the same paint job.

 

Hey Wiz - is this one blowing any smoke? Rings in #1 might just be gummed up and in need of a good run.

 

No smoke, Hillsy, I have put the valves in speck & put a set of the correct plugs in, so this arvo I will fire her up & report results.

 

Ahh - let me guess.

BPR7ES instead of BPR8ES ??

 

Almost, they were 8s but without the R

 

Future challenges.......................

 

WOW 8O

How the hell did it rip the centre stand mount off like that????

 

...and...that crossbar would also have some structural significance for the frame I would imagine. A sort of brace as well as a mount for the centrestand.

Cornering hard would be interesting - perhaps a little seasickness as it wallows in the corners...

 

We CAN rebuild it, we have the technology. 8)

 

Has anyone replaced the perspex in the meter housing?

 

I have a scrap FJ600 cluster that looks very similar, I'll dig it out and see what's left of it.

The instruments themselves are glass lenses, aren't they?

 

Another interesting thread from Wizard..........life is good!

 

I am in the process of repairing the meter housing, Fitz & will post the how to pics' shortly. Wiz.

 

With the fairing support, I have buzzed off all the cable clips & cut off the indicator brackets, I will have bullet type indicators mounted on the fairing.

 

Straight to the pool room.... :lol:

Nice work :wink:

 

Cluster casing repair.
I used gaffer tape to form the shape on the inside of the casing, folded masking tape stuck to the gaffer forms an edge, sprinkle the Q Bond powder onto the gaffer tape & add hardener, build up a few layers, trim the gaffer, sand smooth & finish with fine surface filler, final rub down with 240 wet & dry, mask up & spray with bumper / trim paint.
Formed new perspex lower panel, harvested & transplanted the hour / min' buttons ( that was the hard bit)

 

as inspector gadget would say, Wowzers!"

 

Fender repair pictures, note the previous welded repair.

 

some stupendous welding I may say, perhaps by head mechanic Helen Keller?

 

Never done any plastic welding have you Schoot? :lol:

(that looks pretty solid, actually :wink: )

 

oh plastic welding, lol, that dark red looked like rust to me.. makes sense now... it looked like some welder just drug his tip along the line, no cross hashing or anything like that makes sense now..

 

What's been going on here then?
Where are the 3 wise men (mi carl, robert, polock?)

 

What are we looking at? The 4 crimp terminals off the black wires? I'd say they're all earths - maybe the PO had electrical problems and was trying to eliminate bad earthing?

 

That's part of it Hillsy, but it's the 2 relays looks like they have been hooked up together & one wire cut out of each.

 

maybe one set of contacts is bad in one and the other set in the second one and it was expeditious problem-solving?

What relay is/are those?

 

I can't identify them, Fitz. They seem to have been lashed onto the loom.
The reds go to the starter relay.
The black is ground.
Green to left h/ bar controls.
Yellow to head light bulb.
Brown to headlight bulb.
Help !!!

 

Sounds like a high beam relay.... Bike didn't have driving lights fitted at some point did it?

 

i'll take a guess, the PO used the relays to power the headlight (higher wattage bulb ?) took the power from the starter relay to drive the bulbs and used the original headlight wires to run the relays
makes for a bright light, bypassing the original harness with big wire
when do you find time to go for a ride ?

 

Much like's Tom's comment in this thread...

http://www.xjbikes.com/Forums/viewtopic/t=11351.html

 

I was riding yesterday, Polock, I find it clears the mind to deal with electrical problems. :wink:
Right how do we get this back to stockaroony?

 

back to stock...yuck right now i'd figure out exactly what it does or doesn't
do and consider using relays on the headlight, nothing like a bright light in deer country, you do have deer down there right?
i use a trickle charger in place of the battery to make sure everything works
that way you don't melt anything while things get sorted out
unplug the voltage reg and tci first

 

No deer, just kangaroos, loom is off the bike, so no danger.

 

The headlight has been fitted with a 100/90 bulb, (stock is 60/55) so that was what that was all about, NOW, do I leave the big amp bulb in there or chop it back to stock?

 

Leave it... You know you want to

 

The usual XJ fuse box............

 

Hey Wiz - -

Can't you just pick up a loom off the Aussie Bay ??
I got my complete, perfect wire harness for my 750 for $15.00 (US)
And it came with all the relays and a clean fuse box.
It really turned the project around for me. As in - - everything worked !!

If you don't drive at night much, go with the lower lighting.

 

did anyone ever say "it's fast enough, handles nice but the lights are too bright" ?

 

I think this mod was done by a pro', with the separate 2 wire fused supply & the 2 relays for high & low beam, I think I will leave it as it is.

 

Picture shows piece spliced into the danaged frame member, work stand bracket fabricated, all ready for welding.

 

Very nice!

 

In case you think I have been doing nothing, :wink:

 

I want to know what your wife is going to say when she starts looking for her table cloth!

 

We havn't had a tablecloth since the 'News Chronicle' became the 'Daily Mail'

 

Not even at Christmas? Must be a different Daily Mail!

 

Muffler before & after pics'.

 

Final drive / swing arm, finished.

 

It's not often we get to look at our bikes from this angle, but if we could, what would we find?
Marked in red, was a 6mm hole which when investigated had very little metal around it, we dented the thin metal in & welded a bar in there.
Blue is the new work stand bracket welded in place.
Green was another small hole.
So we probably don't know what we are riding around on. 8O