Picked up my first XJ....free

So I grabbed the free '81 XJ550 Seca today. For the cost of the tow, this baby is now mine. I planned to get it running for a friend, but after seeing the condition it's in, I think a complete tear down is in order.

The PO rode this about 18 months ago, and then let it sit for all that time uncovered in Brooklyn! Not good.

I'm totally new to these bikes, so all help in much appreciated.

This is going to take some work, but hopefully with your help, I can bring her back to life.

Couple quick questions/observations:

I read in the FAQ section on carb cleaning that most XJs came with Hitachi carbs. This bike has Mikuni carbs on it. Is this aftermarket?

I can't believe there is no kick starter! Is there a way to move the oil around to get the it flowing through the cases?

How the heck are you supposed to see through the oil "window" to check level??? It's completely clouded. No dipstick???

Is there a way to bypass the kill switch for testing purposes only. Maybe just kill the engine with the key for now? Because the kill switch seems to be swinging without resistance on the three positions. Afraid this would not allow me to know whether I was trying to get the bike started with the kill switch inadvertently killing the engine

The PO changed 2 of the old fuses to the blade type. I saw that he has a 20 amp in there, and a few 30 amps floating loose. I thought I had read that the correct fuses were 3x10 amps and a 20 for the main. Please confirm.

Does anyone know of a color wiring diagram for this thing? I have one for my '76 CB550, and it's priceless!

I'm sure there will be more.....

Thanks for your time.

Scott

 

Welcome to you and your new opportunity. Highly recommend you pick up a maintenance manual on your model. Looks pretty neglected but with a lot of reading (this site is a REALLY good resource), you can lick any problem you might encounter.
Best of luck!

 

Get the XJ CD. $10 and you will have a wealth of info.

The 550 had Mikuni carbs stock. The fuse block issue is a common problem with the XJ. Most replace them with inline fuse or a generic fuse block. No there is no dipstick. The metal will show thru if the oil falls below the accepted level.

 

Good luck on your rebuild.

I got my 82 Seca 750 for $850. Came with hard saddlebags, fairing and cover. And in running order.

I look forward to reading about your work.

 

Thanks folks! I'm really looking forward to this. It's a daunting task, having not heard the thing kick over. Im used to having a kick starter to check compression. Also, the problems with the kill switch may make basic testing tough.

I'm going to fix the fuses tomorrow with a box I picked up today.

I grabbed a copy of the manual - but it's an old PDF scan, so tough to see certain photos.

This CD you mention, it's an instructional/wrenching CD? Is it just documents?

Also, can someone point me to a carb overhaul thread for these Mikuni carbs. I only see that one tutorial in the FAQ.

Appreciate your help.

Scott

 

PM me with your email address and I can get you wiring and cable placement diagrams, as well as some pics of what it's supposed to look like under the seat.

 

Go to this site for details on the XJ CD.

http://www.xjcd.org

Look at the bottom of the page for the What is the XJCD. If you own an XJ, you won;t be dissapointed.

 

Thanks so much! Looks like a great resource.

 

you got yourself a project there . Its a really good way to learn the bike before you ride it

 

You have a nice project there. Take your time and don't get discouraged. My project 550 looked a lot worse than that when I started. I am down to painting it now. Before you try to start it, change the oil and filter. Make sure there is no water in the motor. That tank looks salvageable. Don't just trash it. They are not easy to come by. I have over 30 hours into just my tank alone. You are gonna love this bike when you get it on the road again. Just don't cut any corners on the rebuild. I'd say it was sitting a lot longer than 18 months too from all the rust on it. Mine sat outside for 13 years and didn't have that much.

 

It's definitely got potential. Heck, it even has a right hand sidecover! That is a miracle in and of itself.

I got your PM, watch your email for a whole bunch of info, pulling it together now.

Somebody cared about the bike at one point, it appears to have a stainless front brake line.

Except for the bodywork, my '81 was in about the same condition when I got it: Rusty old 4-1, all the polished stuff corroded grey (mine was actually a tad worse if you can believe that,) and look how it turned out:



And I can tell you it took a lot more work than money to get it looking and running the way it does now.

 

Thanks big Fitz. Your bike looks smokin!

I knew I was in for some pain with this one But I don't mind the elbow grease, it's the cash I'd like to keep to a minimum.

I have a decent collection of tools already, so hopefully there will only be a small amount of specialty tools I need. Already I see there are a few things (YICA tool??? Etc) that are new to this bike that I'll have to pick up.

That side cover actually has a missing tab I think. And I don't have the left cover. Are they as hard to find as I imagine they would be?

The PO really did love it in his own way. He insisted I give him updates on my progress, complete with pictures. He put the SS brakes cables on there shortly before calling it quits. He had it serviced by a place right near me, so I would hope that the rear brake was safe as well.

I really appreciate all the help.

Scott

 

Nortstudio - welcome and best wishes. Please keep us posted with pics of your progress. This is the kind of stuff that we love to see.

Fitz - your work is truly an inspiration to me! I am just getting started on my 550 project and I think I would be happy if it turns out half as nice as either of yours. From the factory, are the rear foot peg mounts aluminum?
What about the lower fork tubes? They seem to be anodized. Are the mufferls on the white one stock? The PO of my 550 put some kind of shortys on. Were your headers as rusty and nortstudio's?

 

Thanks Mirco, I'll definitely keep photos coming. Hopefully they will show progressive improvement

There is some serious rust on thismthing after 12-18 months of sitting, but nothing hat some hard work and wet/dry won't cure.

I'm doing some similar things on another bike of mine, so I am getting my arms well warmed up for this gig!

 

The rear footpeg/muffler mounts were "natural" aluminum on the '81s, and Yamaha's ubiquitous low-gloss black on the '82s and '83s.

The lower fork tubes were likewise natural aluminum on the '81s, and gloss black on the '82s and '83s. Mine look "anodized" because that's the original lacquer coating gone a bit yellowed, but they're in such good shape I left it until it starts to peel off. Then I'll strip them and refinish them.

The mufflers (and the rest of the exhaust system) on both of mine are completely stock. It's a major part of the "streak-flash-bam! magic" of the 550 Seca. My '81 came with a thoroughly rusted Kerker 4-1 with an open megaphone and it hadn't been rejetted for it. The bike was ungodly loud, and pretty much "ran out of steam" just when things get good, above about 7K rpm. With the stock exhaust, it was quickly transformed back into the little rocket that so impressed the world when first introduced.

Cycle magazine cover, February 1981: "Yamaha's New Seca 550- A Lightweight Sensation With 750 Sting"

Cycle World magazine cover, April 1981: "Yamaha 550 Seca... Daytona Spirit, 750 Muscle"

Put it back to stock, get it running right, and you'll see what they were talking about.

You can also kick it up a notch; motor's stock but not the seat, suspension, instruments, brakes, signals and various other details, etc:



The rear peg mounts on this bike are black, it's only a trick of the light that made them look lighter in this one pic.

 

That bike is gorgeous!

 

Thanks. It had to have a lot more things replaced than the '81 did, it had much lower mileage so it did a lot more sitting. Plus, it had a bent clutch basket from a right-side tipover.

Believe me, it rides as nice as it looks.

 

I don't doubt that thing rides like a dream. I found out this one has about 25,000 miles on it. I'm sitting here staring at it, and it's looking more like a nightmare, and less like a dream!

 

Like I said, except for the body work, my white bike was worse. I got it at 18K, it's at around 27K now. As long as the motor is tight, you're in good shape. Everything else is just methodical work.

I have a 650 that started out in about the same shape; it's slowly being resurrected.

 

It's fun if you can make the time to work on it. Lots of polishing and sanding. If you are good with paint and can wait a little while to ride, it'll be worth it.

 

I have a CB I've been refurbing, which I ride all the time (even thru this northeast winter this year!). So I've got a daily rider for now.

I have time, but would love to get this thing going ASAP, so that my friend can ride it. Fun for me, fun for him, if I can get it straight.

 

bigfitz - hv u put any pics of the 650 online yet? would luv to hv a look at how its progressing (judging by the your 550s it will turn out great!

 

Well, I put some single waterproof blade type fuse holders in there, to match the two that were already done. Put the correct fuse sizes in

Had charged the battery overnight, but I think it's shot. It measured about 12.8 when I took it off the tender. But the fluid is so high, I fear the PO may have really messed it up.

I put the battery in anyway, just to check if it would give me any info. The blinkers worked, but no headlight. Didn't check brake lights.

I got the kill switch to what "seemed" like run (the thing is fried!) and tried to turn it over. No dice.

Question: I had the kickstand up in case this has a safety feature, and tried to get it into neutral (in case it has that function too) but still no dice.

It's feeling like the tranny is acting weird. Keeps clicking as I push down on the shifter, but never feels like it goes through a neutral. Tried pulling half up to find it, but in fact it never feels to go into another gear up from all the way down (first).

Am I missing anything that would allow me to even see if it would turn over?

I realize I'm getting ahead of myself, but for some reason, I've always felt like I can't move forward until I at least hear it crank over. Makes no sense, I know. Weird obsession.

Thanks.

 

Turns out after putting the battery in, the brake lights were on the whole day. I couldn't see it in the sun!

So now, even weirder than getting no juice to the motor, the brake light is on, with no key in ignition.....

 

good luck with the project! i also started out with a freeby XJ (900). It was a frame that kinda rolled and a few boxes of bits. Lots of effort and a few dollars later (not as much as i thought) and its all done.

Love this pic - shows that a bit of elbow grease can give great results!


the finished product - not bad for a basket case and AU$800 including first rego!



keep us posted with this project - it will be great to see how you go with it.
Tim.

 

Sorry I've been so out of the loop. I did a compression test on 2 cylinder (then the solenoid overheated) with some horrible results. #1 measures 60, #2 hit only 30. Not good!

Then of course I got hammered by a cold. Just now getting over it, and work is going to keep me away from her until next week.

Started thinking that it may be best to part it out. I can see the beauty through the mess, but with a few strikes against it (ignition system, engine AND cosmetic), might just be too much.

Your bike looks gorgeous - and makes it hard to give up on this puppy. We will see what next week brings.

 

It's all just a matter of how much work you want to do.

If you pop the valve cover and watch as you turn the motor over, you should be able to tell if any valves are stuck open (EXCESSIVE clearances) which could cause poor compression numbers. If all of the valve clearances are in spec or close, then at that point you know something worse is wrong. Then you can decide whether to pull the head and look or give up on that motor.

 

Thanks Fitz. I will get a chance to do this sometime next week. Locked away at work until then (ugh!). I'm anxious to see what's happening in there for sure.

I'll let you know how it goes.

 

quick question - anyone have a picture showing the correct decal clours for a 1982 XJ550RJ Red USA - if I go to the trouble want to make sure it is right - by the way - pretty happy with the red paint job on mine - maybe you could consider doing the same - check my pics ( the one taken in the garage is the finished product lol ) enjoy the rebuild it's like building plastic models as a child lol

 

This one's stock: http://xjbikes.com/Forums/viewtopic/t=35754.html The stripes look white but they're actually an odd silver color.

Nothing like dragging up an old thread. The guy who started this thread gave up; the motor was beyond hope, the bike just too far gone.

But anyway, the bike in the link I posted above is the stock color scheme. I always felt the red was a little lifeless and it didn't seem like they gave any real thought to the placement of the sidecover stripes and badges. Both '81 and '83's stripes made more sense, IMHO.

If you decide to go back to the stock scheme; be careful: there are two decal sets out there for that bike; one is very close and one is way wrong.

 

put some marvel oil, or pb blaster, or kroil in the cylinders and spin it over a couple times. Let it sit a day, spray some more in the next day, and do another compression test.....possible that rings are sticking.............................

Dave Fox