Finally finished!

Here's a pic of my finished XJ650 project. Finally I can just hop on and ride it.

It would take three pages to list all the things I've done to this since I got it. I was originally going to just remove the "bobbing" and restore it to stock but I think I overshot it a little. (see my sig and bigger picture in my gallery)

I never could have done it without all the great expert help on these forums.

Now to start tearing down the Kaw...

 

That looks like one SWEET ride you made there, Gitbox. Ride with pride. You've earned it!

 

agreed... looking great! can't wait till my 650 is on the road!

 

OOhh, Seca instruments. Did you hook up the voltmeter? They're one of my best buddies...

 

Thanks for the nice comments. I'd have more time to clean it up if I didn't RIDE it so much. (hehe)

Yes, Fitz, I did. And the fuel gauge, too. I had to design a circuit to adapt the XJ750 fuel sender to the XJ550 fuel gauge but it works GREAT! Also, I had to find an electronic tach that would fit in the cluster. That was tricky. More customization. I think it's from an XJ700.

I'm still amazed how all the other stuff just bolted right on - and worked.

Oh yeah, and now I have left and right signal indicators - SWEET.

 

I've got one, from an XJ/FJ 600 I think, that I want to install. Biggest challenge appears to be creating a "mounting block" for the electronic unit as it isn't as deep as the mechanical unit.

I was thinking about cutting the corresponding area out of the cluster the tach came in and transplanting part of it into the Seca 550 cluster.

What did you do?

 

Glad you asked, Fitz. I actually need to take the cluster off to replace some indicator lights (I think I may go LED) so I'll take some pics and post them. Heck, I might as well do that later today since it's 32 freakin' degrees here. Well, at least the sun is shining.

 

can you tell me what that style of handlebar is called?
I love the style but can't seem to lay my hands on a set

 

Sorry, mack, I couldn't tell you what the style is called. Cruiser? Pullback? I'm sure someone on this forum knows. All I know is that it's pure stock.

Funny you mentioned that because the riding position is one thing I always loved about this style bike. The handlebars feel so natural and comfortable.

 

Yeah I know mine are stock as well, but they don't have the rise and down turn that I like.

 

thats a beauty, i really like your seat., I want to get mine re-done like that. could you tell more more about it(the seat) is that original?

 

I thinks some call them buckhorns, but if that is the "official" name i do not know. I do know that i have them on my XS750 and i am somewhat indifferent to them.

 

Good Job, Gitbox. I like them restored back to their original beauty!

Where'd you get those original pipes? They look like they are in great shape!

 

Xdjfrick, the seat is original, that is I got it with an '81 XJ650 partial frame and engine that I bought at a salvage yard. The PO had cut the frame on mine from the shocks rearward to install a Harley type fender and single seat.

 

Thanks, Skippy. I pieced them together from three different sets. I picked the best headers and mufflers of the bunch. They look pretty good but they have some stains on the chrome and the crossover section is fairly dinged up and rusty. Also, the little heat guards are loose and vibrate at a certain RPM.

But I'm being picky. I should be thankful I got these since a set in excellent condition is rare as rocking horse poop.

I still have the MAC 4-2 set that came with the bike and they are in excellent shape, but I didn't like the side turnout mufflers, plus they're a bit loud. If I find megaphone style mufflers that fit and look close to stock, I'll put them on.

 

For the benefit of Fitz, here are the tachometer fitting pics:

Oh and Fitz, does your battery and fuel gauge light up well at night with the standard 194 bulbs? I can see the speedo and tach fine but the gauges look barely lit.

 

AHA! NICE job, very solid. I may go the "standoff route too. I'm also a big fan of those black plugs.

I replaced the INSTRUMENT (only) lamps with 5-LED "914's" and it made a world of difference.

I used these: http://www.hipoparts.com/product_info.p ... cts_id=572

The original 194's are plenty bright in the indicators.

 

Thanks. A bit of a pain but worth it.

Did you use yellow LED's for the signal indicators, red for the oil, green for neutral, and blue for high beam? Or did you use just white for all of them? Also, can you backlight the panel with a different color such as red or is it only going to show green no matter what? Oh, yeah and did you use LED's for the brake and signal lights? If so, which ones?

I want to convert everything to LED's for reliability and visibility improvement. I'm not worried about the self canceling feature. It screws me up anyway when I ride the Kaw.

 

I replaced ONLY the instrument illumination lamps with LEDs; I left (new) 194's in the indicators as the LEDs were just TOO bright in them.

The gauges will "backlight" with whatever color is molded into the translucent face before the black and white was silkscreened on. The stock 550 Seca gauges were printed on yellow faces.