First Bike, 82 XJ550

Hey Everyone, new rider here. I thought I would introduce myself because I think I'll be on this site a lot. I bought a 1982 XJ550 for $375 the other day for my first bike and she needs some work. There's about 20k on the odo and the previous owner was pretty rough with the bike. Anything I should be looking out for that is typical of these bikes?

The picture below doesn't show the seat, but it came with the bike. it looks as if its been through a blender though. the clutch was frozen stiff at the lever, not sure if the cable is just destroyed or if there is something else going on with it. ideas? also the choke isnt working, but im almost positive its just a cable issue. those are the only mechanical problems that I'm aware of with the bike, the rest are just cosmetic. needs new sprockets and chain too, but that's pretty straight forward.

what are the first things I should check out when fixing this thing up? there are new plugs and fresh oil, but id be willing to bet that any other maintenance has been neglected.

 

First off, welcome to the site from VA. Before you ride the bike check the brakes for delamination. (Do a search) Make sure the valves are in spec. and carbs are in good shape. I would go over everything since you said the PO was rough with the bike. That way youo know it has been done for sure. I'm sure someone else will chime in also but nice bike and welcome again.

 

Check the date on the tires and front brake lines as well as what lost it said. Lines over 4 years and tires over 5 years NEED to be replaced.

Making sure it Is safe if the most important factor to consider when putting a 30 year old + bike back on the road.

Congrats on the purchase and welcome!

 

Well, since you asked; here's a basic list:

- check tires, condition, and date codes.

- inspect wheel rims for damage or excessive runout.

- check front brake pads.

- inspect disc brake calipers for damage, wear (thickness), or excessive warpage/runout.

- VISUALLY check rear brake shoes for wear/delamination; adjust rear brake pedal linkage. This is very important. Delamination is common, the only way to detect it is to SEE it. http://xjbikes.com/Forums/viewtopic/t=15874.html

- inspect/lube/adjust/replace final drive chain and sprockets. Keep an eye on the chain. If it "bleeds red" when being lubed and won't hold adjustment, it's rusted internally and will need to be replaced. Always replace both sprockets with a chain.

- check and adjust if needed operation of front and rear brake light switches.

- replace rubber brake hoses (check the mfg date stamped in them).

- unless known to be otherwise, plan on rebuilding the brake master cylinder and caliper(s).

- check and clean/replace the air filter element.

- change all fluids: fork oil, engine oil, and brake fluid.

- check and repair any engine or drivetrain/suspension fluid leaks.

NOTE: almost any original oil seal or engine case gasket will need to be replaced when its cover is removed for the first time.

- check and adjust/lubricate/replace steering head bearings.

- check and adjust/lubricate/control cables and speedometer and tachometer (if applicable) drive cables..

- check and adjust/replace rear shock absorbers.

- electrical system inspection, replace fusebox and most probably alternator brushes.

- check battery condition; replenish fluid (distilled water only!).

- clean the battery terminals.

- check all lights for proper operation and brightness (headlight, tail/brake light, turn signals, dash illumination).

- check horns for proper operation and loudness.

- check stator resistance.

- check rotor resistance.

- check battery.

- check coil primary, secondary, plug caps resistance.

- check engine cylinder compression; record your findings.

- check and adjust camchain tensioner.

- check and adjust valve clearances; record your findings. http://xjbikes.com/Forums/viewtopic/t=14827.html

- drain carbs, check for foreign matter in bowls, install in-line fuel filter.

- check function/operation of fuel petcock; correct any leaks and/or rebuild the petcock if indicated.

After all that (and having corrected anything that needed attention along the way,)

-Install a new set of properly gapped NGK D8EA spark plugs, and with a fully charged battery, clean air filter, fresh gas and a little luck it might fire up.

Nothin' to it.

Best practice is to get a service manual, factory or the Clymer, and go through the "maintenance" section, item by item, leaving nothing out, skipping over nothing, taking no shortcuts; do it all.

Once you do that, you'll have a bike that's safe, reliable, economical and fun to ride. Anything you miss will simply MAKE you do it eventually anyway.

 

wow, thanks a ton guys. I've got more work ahead of me than I thought. that's quite a list there Fitz. Ill be posting more as the restoration continues.

 

Welcome to XJBikes! from the Boston Mountains of Northwest Arkansas!

First: Get yourself more than one manual (Clymer/Haynes and/or Factory) for guidance-you will need these

Second: Research your bike on this site and read about the most critical things we all run into with these old classics

Third: Take your time and start by cleaning your bike and identifying what you need to work on first. This will develop your relationship w/the bike-critical first step

Finally go through all the maintenance step by step. Bigfitz's list covers what is most important. It seems long but much of it is a quick process. Stop in here and ask away for anything that doesn't seem clear or easy. Someone has been there and can guide you to the light. Then your good to go. Enjoy the ride, post pictures, share your experience, and it will be time for project #2 and start all over

PS - shop around if you need parts and come here first-there are a lot of rip offs out there and we won't let that happen to you.

 

Two really good points here:

By all means get it cleaned up first. You can't work on a grubby machine; you don't want to drag dirt or grit into the innards and it allows you to see what's actually in need of attention. Cleaning each and every piece you touch is half the battle/half the fun of setting these bikes right.

Then, armed with even only the owner's manual (which is pretty "brief") you can accomplish about half of the stuff on the list in the span of a couple of hours. There are only a few "major" service procedures involved; plus quite a few mostly small parts that will need to be replaced (mostly brake parts and gaskets.) There's alot you can do while waiting for the service manual you ordered to get there.

The aftermarket book for the 550s is by Clymer; and factory manuals are easily sourced on eBay or through XJ4Ever. Speaking of XJ4Ever, (logo/link in site banner, upper right) that's THE best source for the correct parts for these bikes at fair prices. YES, you can find cheaper parts; but be careful, there is a LOT of incorrect stuff running around out there and eBay sellers are largely clueless or worse.

If you're going to do a proper "recommissioning" plan on investing somewhere in the range of $600~$800 after all is said and done; you're going to NEED to replace things like brake lines, shoes, tires more than 5 years old, etc. Things like new shocks, upgraded fork springs, etc., can wait. Safety items can't; and reliability is next. Cosmetics can wait until the bike stops and goes.

 

You are a lucky man I would kill to find that bike for $375 It would give me a treasure trove of spare parts for mine.