My First Bike-- 81 Maxim 550--FINISHED

Just picked her up yesterday! Was ridden all summer but needs some cosmetic work done. Going to rip it apart this winter and clean it up, rebuild it, and probably redo the paint on it. Can't wait! Pics from the resto to follow.

 

Re: My First Bike-- 81 Maxim 550

Great looking bike! I'm sure you'll have fun with it.

Welcome to the forums

 

Re: My First Bike-- 81 Maxim 550

welcome to the forums, looks like a fine place to start with a bike. was the bike previously ridden or was it sitting for some time??

 

Re: My First Bike-- 81 Maxim 550

You still need to check the standard stuff, starting with the rear brake: http://xjbikes.com/Forums/viewtopic/t=15874.html

Just because PO was riding it, doesn't mean it doesn't have beaucoup safety issues. PO was riding my '81 when I bought it, and as soon as I saw the consistency of what used to be brake fluid in the M/C reservoir, I parked it until I had gone through it myself. (Good thing too.)

Don't assume a running bike is a: safe or b: reliable until you've checked it yourself. (Including the valves and the carb sync, if you want it to stay running.)

 

Re: My First Bike-- 81 Maxim 550

+1 on your post fitz, I was just curious as to how he got it.

 

Re: My First Bike-- 81 Maxim 550

I was going by the fact that he said "was ridden all summer."

My point, that doesn't make it safe OR reliable, was a lesson I quickly learned when I bought my XJ.

The list of things my bike needed, and then ended up needing, is in my response to this thread: http://xjbikes.com/Forums/viewtopic/t=2 ... rt=30.html

A lot of others took the time to post all of the things they needed to do/had done/still need to do; it's pretty interesting reading and you will see what the common issues are.

Now go check the rear brake, as in TAKE IT APART and inspect the shoes.

 

Re: My First Bike-- 81 Maxim 550

It had been ridden until June when the license tag ran out. Fitz, I do agree this doesn't make it safe or reliable. I have been searching this forum religiously since I started contemplating buying this bike, and your posts have been some of the most informative I've found. I won't be licensing this bike until the spring and plan on tearing it down over the winter for a (almost) total rebuild and restoration so I will be sure to check all those things that you have brought up. CMCcully, I found the bike on Kijiji, and went and picked it up in London, Ontario, about 2 hours from my home. Thanks for the input guys, glad to finally starting as a rider as opposed to just a reader. Gotta finish up a job I'm doing right now, then make some room in the garage, and then the fun begins.

 

Re: My First Bike-- 81 Maxim 550

Excellent. Much easier to begin a resto or resurrection even with a running bike.

 

Re: My First Bike-- 81 Maxim 550

+1 on that..... I sank about 500 bux into my build before I even knew if the motor ran. least you have some piece of mind before sinking money into it.

 

Re: My First Bike-- 81 Maxim 550

Nice lookin' ride. I've put 1000.00 into mine so far and will probably put another 1500.00 when I finish but it'll be exactly what I want.

 

Re: My First Bike-- 81 Maxim 550

well thats the important thing. as long as your happy and its what you want, then go crazy!

 

Re: My First Bike-- 81 Maxim 550

Ok, so some questions in anticipation of my resto. First off, you can see in the first picture that the signal light is hanging on by a thread. 2 of the other lights have similar electrical tape components lol. Is there a place to purchase replacement flex pieces for the signal lights or dou you have to replace the whole housing?

Also, I was thinking about re-routing the wiring through the inside of the frame to tidy up the bike a bit. Has anyone done this and would this cause any problems besides lack of access to the wires? Thanks for the help.

 

Re: My First Bike-- 81 Maxim 550

as for the turn signals, if you just want stock is to hit the classified on here, or go to ebay for a used set off of a parts bike. you shouldnt have much more than $15 invested with shipping.

As for running the wires through the frame, its not as easy as the chopper shows make it look. actually it is down right Difficult on a stock frame, becuase of all the bends and changes. If you want to though go for it, best of luck, and I wish you the best on it.

 

Re: My First Bike-- 81 Maxim 550

With new signals you get new sockets,bulbs,wires,stems and hardware. Also less headaches and you can customize too.

 

Re: My First Bike-- 81 Maxim 550

You can check with chacal (see the XJ4Ever logo on the banner, upper right of this web page) for virtually any part, plus Yamaha still offers the rubber stalk: http://www.babbittsonline.com/pages/par ... fault.aspx if you want to pay way too much.

Sound advice on the "wires through the frame" thing. If you just restore the bike back to stock trim you won't see many wires. I wouldn't start drilling holes in the frame.

PM me with your email address and I can shoot you off the cable routing guides from the factory Maxim book.

 

Re: My First Bike-- 81 Maxim 550

Finally got to start work on it tonight. Took the signal lights off and found out that 2 of the lens screws had broken off inside the housing so I might need a new set of signal lights if I can't get them out. Got the mirrors, tank and headlight off, and was about to remove the passenger pegs and start disassembling the rear brake to check for delam when I snapped the bolt on the rear brake lever. Balls! I'm guessing there is a groove on the shaft that that bolt sits in, and you can't get the lever off until that screw is out, right? I'm guessing I'll have to drill out the screw and all that fun stuff. Anyways, got a couple pics of the progress so far.

 

Re: My First Bike-- 81 Maxim 550

I would give you my turn signals but the same thing happen to mine... And if we are talking about the same bolt on the brake mine broke also. When I was workign on my back brakes the bolt on the brake lever that acts as a stop broke. In my case I just left it. It was tricky putting a new cotter pin back in the rod to the drum but it was do able.

 

Re: My First Bike-- 81 Maxim 550

I don't think we're talking about the same bolt. The one I'm talking about is the one that tightens the brake lever onto the shaft. Don't know how else to explain it lol. I'll get a pic tomorrow.

 

Re: My First Bike-- 81 Maxim 550

OH, yea, not the same. ouch, good luck drilling that out. I am not even sure what the best was of getting that out would be. There is a small groove I belive.

 

Re: My First Bike-- 81 Maxim 550

Fun fact for the day. One of the POs painted all the wires black. Looks nice, gonna suck having to label them all...

 

Re: My First Bike-- 81 Maxim 550

Ahh it wont be to bad. The po of mine painted EVERY THING... Over spray on everything lol. Tires, wires, the old headlight,the sight on the mc and engine oil level lol.

 

Re: My First Bike-- 81 Maxim 550

Spent the afternoon tearing her down some more. Not too many setbacks, although I was just about sick every time the exhaust flange nuts "cracked". Pulled the exhaust, rear wheel, chain guards, and front fender. Problems so far: My exhaust collector is toast, rusted out pretty good, and one of the mufflers is stuck on there still. Can someone help me out, a torch will ruin the chrome if i try to loosen it off that way, right?
Pulled the rear brake apart, lots of dust built up, not sure if that counts and de-lamination or not.
You can see in the one pic that there is a fair bit of build up around the exhaust ports. Should I be anticipating pulling the head off to get rid of similar deposits on the valves and seating? I was hoping not to pull the engine apart too far if at all.
Also curious about the colour of the area around the front sprocket. It's really sticky, almost like a rubbery paste. Any insight?

Thanks for the help, enjoy!

 

Re: My First Bike-- 81 Maxim 550

Looks as if everything should clean up nicely. Lots of anti-seize on those studs!

 

Re: My First Bike-- 81 Maxim 550

Any thoughts on whether that's an acceptable amount of carbon build-up on the exhaust ports? Or whether a torch will ruin the chrome on the muffler if I try to heat it up to get it off?

 

Re: My First Bike-- 81 Maxim 550

 

Re: My First Bike-- 81 Maxim 550

Man, I hope you know where everything goes taking it apart like that! Keep it organized or you will regret it!

I wish I had the place to do the same thing though, its too much fun.

 

Re: My First Bike-- 81 Maxim 550

Haha ya no worries Ravenz, I got everything ziplocked and labelled, and I got the manual and I've been taking pictures of everything as I disassemble. It is a blast!

 

Re: My First Bike-- 81 Maxim 550

Awesome! Thats how I do it too, but it sucks if you abbreviate something and forget what it means!!! haha Keep us updated! What the plans so far?

 

Re: My First Bike-- 81 Maxim 550

Overhaul for the most part. Everything is probably "safety-worthy" but I figure I can't ride it until spring anyways so I might as well work my way through her, teach myself a few things and tune her up the way I want. The to-do list so far is carb rebuild, petcock rebuild, new fuse box, in-line fuel filter, and then an overall cleaning and re-paint. Hoping to have it on the road by march or april (whenever the snow breaks), but official D-Day is may 13 for the Port Dover ride.

 

Re: My First Bike-- 81 Maxim 550

exhaust build up isn't really an issue, go at it if you want with a wire brush but it's not really an issue. I'd be more concerned about running rich.

 

Re: My First Bike-- 81 Maxim 550

Brakes? Rear shoes, front pads, fluid, hoses?

How old are the tires?

(if you're serious about riding to PD13.)

 

Re: My First Bike-- 81 Maxim 550

Brakes look good, like I said, a bit of dust build-up in the back. Probably going to do a caliper and MC rebuild as well, lots of wear left tho. The tires were within the last 2 or 3 seasons. Still lots of tread. Fitz, do you have a link to one of the delam threads with pics so I can be sure?

 

Re: My First Bike-- 81 Maxim 550

Thought I had already posted it, but here's is my main concern at the moment. Thoughts? Will she hold or should I replace?

 

Re: My First Bike-- 81 Maxim 550

Seems fine, I dont see any holes. It looks like it has some surface rust, but it doesnt seem as though it is enough to weaken the metal. Clean it up and see what it looks like. As of right now though, I wouldnt be concerned.

 

Re: My First Bike-- 81 Maxim 550

I'm just thinking with the broken off tabs on the 2 inlets it might not seal properly... Maybe I am just being anal...

 

Re: My First Bike-- 81 Maxim 550

You're not being anal and it might not seal properly. You're missing more than tabs, the clamps are welded to one of the tabs on each spigot and they're what's missing too.

You can try it and see; I would be concerned that it will leak over time.

 

Re: My First Bike-- 81 Maxim 550

Ya, I've got the clamps at home, although I dont think they came off in one piece. Kind of a redneck fix but I was wondering if some gear clamps would work?

 

Re: My First Bike-- 81 Maxim 550

Also considering getting or making a couple of "Y" pipes to go from 4 to 2, instead of a whole collector box. Will this cause any problems with the back pressure? Has anyone done this before?

 

Re: My First Bike-- 81 Maxim 550

I made 2 2-1 merges for my 650 over the winter. Plenty easy enough if you've got a welder and some simple math skills. Depending on the length you want the merges to take up it's only a couple bucks for the tube.

The mufflers and the rest of the pipe will effect the back pressure too.

I had to up my main fuel jets 2 sizes. I went from a 4-1 to a 4-2 through FLH harley mufflers.

 

Re: My First Bike-- 81 Maxim 550

I've got the stock mufflers, the only thing I would be changing is the collector box to Y pipes, same length.

 

Re: My First Bike-- 81 Maxim 550

Also, where did you get the pipe for yours Iwin?

 

Re: My First Bike-- 81 Maxim 550

I built my pipes. I cut up the 4-1 header I had.

I got my tube and bends from here: http://www.mandrel-bends.com/catalog/

I kept the parts of the header where they meet the head and the top radius. The rest I fabbed.

 

Re: My First Bike-- 81 Maxim 550

The collector box is part of the "magic" of the 550 exhaust. Eliminate that and you very well may need to do some re-jetting. You can pull the mufflers without drastically affecting performance/tuning, because the collector box is doing the the exhaust tuning. It needs the collector though.

Don't use "gear clamps" (hose clamps) get real motorcycle muffler/pipe clamps from a "chopper parts" outlet if you want to try that. They will look similar to the clamps that are still attached to your collector box.

 

Re: My First Bike-- 81 Maxim 550

Progress report after today. Frame is bare, ready for prep and paint. Pulled the valve cover and a bunch of my clearances were too tight. Any way to adjust this or do I just have to get smaller shims? Other than that, pretty much at the turn-around point. Next will be cleaning the engine and carb rebuild.

 

Re: My First Bike-- 81 Maxim 550

Smaller (thinner) shims IS the way to adjust that. The shims have the size printed on the back (in the occasional instance where it's worn off you can simply measure them with a caliper or micrometer) and you use the currently installed shim and current clearance to determine the size of the new shim.

To save you doing a bunch of math, Yamaha published a chart; I included it in the how-to on valve adjustment: http://xjbikes.com/Forums/viewtopic/t=14827.html

 

Re: My First Bike-- 81 Maxim 550

Fitz pulls through once again! Thanks!

 

Re: My First Bike-- 81 Maxim 550

I am working on exhuast right now, I would recomend getting a 4-1 setup. Personally I like them much better. They cost way to much though if your doing a budget build. I have ran into bit of an issue. Last night while working on the exhuast my welder broke. I will have to get that fixed before I can finish it. You can find those collectors on ebay now and them. One thing you may want to try witch I have thought about is buying a used 4-1 collector, and make your own exhuast past the collector. Or if you are going for the stock 4-2 then just finding the original collector. I have seen them go any where from $50 to $100. Can't wait to see your bike finished good luck.

 

Re: My First Bike-- 81 Maxim 550

Thanks Haser. I do wanna keep it with the 4-2 just for cosmetic purposes, I like the look better. I have been bidding on a couple collectors and I just missed out on a whole parts bike in my town that sold last night. I've been told that redesigning the exhaust involves rejetting and such and I really don't want to get into that either. I am keeping my eyes open though, we'll see what happens.

 

Re: My First Bike-- 81 Maxim 550

All the valve clearances were below tolerance, will have some new shims on order first thing after the new year. Valve train looks to be in good shape. Have to get the valve cover cleaned up and painted, and then send the frame for powder coating sometime in the next couple weeks and she'll be ready to go back together.

 

Re: My First Bike-- 81 Maxim 550

Save me going back through four pages of postings, how many miles on this puppy again? Just asking as a frame of reference to make a point about neglected valves; good going.

A word about the frame: Exactly how BAD is it? Quite often, what appears to be rust is really dirt, or rust from other parts, not the frame itself. I recommend thoroughly cleaning it, as in old toothbrush and mineral spirits, and then assessing the situation. If less than 10% of it really needs paint, then fix those areas and repaint it.

Personally, I don't recommend powder coating for frames, and here's why: You will pick up an occasional stone chip; it's inevitable. Then you'll be faced with how to touch up the chip in the powder coat-- paint? The only REAL way to "fix" a powder-coat finish is to re-bake it.

IMHO, (and it's not just me, look in Wiz's "It Begins Again" thread in "Other Motorcycles") the best thing for frames is a high-quality automotive rattle-can black enamel. Looks great, easily touched up. Just be sure you wait until the paint cures completely before reassembly, which can sometimes take 10-15 days.

I'm not saying that powder coating has no application, just the opposite; I've got a bunch of powder-coated bits on my black bike and they look great. But they're not in a position where they would take the kind of beating the frame does.