XJ550 Euro, Cafe Styled-Project.

Hi everybody, Would like to start of to say THANK YOU for such an exemplary, and large, knowledge base you all have and shares!

Here's my XJ550 from 1982 (SECA).
Not in the best of conditions after 60000+km, re-painted (poorly), running an ugly "simons" muffler, some other minor things broken,
there's rust on the frame (hopefully nothing serious).
Missing the airbox (ordered a replacement), PO ran pods instead.
And it's not getting any fuel to the carbs (only one carb is getting fuel) probably because it has been standing in a garage for the last 3-4 years.
So right now I'm in the business of dismantling and cleaning the carbs

But hey, the rear wheel is brand new and everything electrical is working (And I just paid about $600 for it, which in Sweden is pretty much as low as you get them if your not buying a wrecked bike)


Anyways, After the carb tune-up and when I'm shure it's running as it should I'm going to strip it down,
sandblast the frame and gas-tank,
repair some damage to the side covers,
change out the speedo and tach for some smaller ones,
add some custom lights in place for the turnsignal, neutral etc.
Move the headlight down a bit,
change the handlebars to some clubmans,
rebuild the mastercylinder,
go over the brakes front and back.
Replace the rear springs and shocks,
Either polish or repaint the rims,
remove the passenger pegs, replace the original pegs with some new, maybe adjust the position as well.
Build a new seat in to the cafe style with the classic hump in the back, which includes new rear light and some modification to the rear end of the frame and to build a new rear fender.
If I don't find anything wrong with the engine and the clutch I will leave them be for now (except for some exterior polishing and maybe some paint).

So a lot of work is going down under this winter to get it ready for spring time!

Picture from the previous owner

 

Re: Introduction and/or project thread.

Welcome.

 

Re: Introduction and/or project thread.

welcome, sounds like a good start and some good ideas to get moving on.

 

Re: Introduction and/or project thread.

Thank you!

 

Re: Introduction and/or project thread.

Welcome from Denver, CO! There are plenty of pictures and advice in this forum, use the search function and look at the galleries for ideas and tips as well as how to's.

Massimo

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Thanks, sure will do!


I can't find any larger quantities if carb cleaner. So I was wondering can I use pure gasoline (chemical gasoline) to soak them in?

(edit, no pure gasoline didn't do the trick neither did Diesel, but citric acid did the trick just fine)

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

welcome!!

carb cleaner has to be availible someeeeewhere

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Thanks!
Actually I did get carb cleaner, but only in pressurized cans, and quite expensive on that..

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Do NOT submerge the carbs in anything unless you have them completely stripped (as in, throttle shaft seals removed.)

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Yeah, that would be a bad idea, especially when the diaphragms assembly costs a minor fortune to replace.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleanin

Just got through my first carb strip down and rebuild, also on an xj550.

I got a second rack cheap and used the best of both to make a good set. One spin off benefit is that having a complete set meant I couldn't forget how to assemble it! Without that I think I would have needed a hell of a lot more pics so get your camera ready.

I ended up buying an ultrasonic cleaner on ebay which was just big enough to get a rack in. Very glad I did, made a fantastic job of cleaning them up.

At the end of the job, went re-installed and ready to test.... petrol p****sed out of no.1 carb into the pod. My heart sank but having turned off the fuel I gave the bike a wipe over and started it just to see if she would fire. For the first time ever, she fired straight away Better still, after running, carb one didnt leak when I turn the petrol back on. Think the float valve was just a bit dry.

Got the final tuning to do still as putting new silencers on but really hopeful that the jobs a good'n.

One other little tip. If you are going from pods to an airbox, you might need to change the main jets back to standard and check the needle position. If you have ajustable needles, don't really solely on the slots, double check that the needles are actually the same length. If the needle isnt seated quite right it will not be the same lenth as the others so double check them by standing upright next to each other.

Good luck... bet those spares cost a packet!

Stu

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleanin

Might want to check valve lash while you got the cover off.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Thanks for the tips!


Will think about the ultrasonic cleaner, the thing is There isn't one here in Sweden worth the money at the moment. (just the industrial ones, and they costs like 3 times more then what I paid for the bike -..)

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

DO NOT "HONE" the throttle shaft holes, unless you want to be looking for new carb bodies!

DO NOT DO ANYTHING to the carbs that involves the removal of metal. DO NOT polish Mikuni slides, they are coated with some magical plastic/teflon/kryptonite and you do NOT want to damage it. Polish the slide bores only if they are greyed or corroded.

In most cases, a rag with a good carb cleaner on it will accomplish what actually NEEDS to be done.

Use big nylon bristles plucked from a parts-cleaning brush to poke through passages, never use anything (like a guitar string or a drill bit) that can actually scratch or move the metal of the carb body, and they're SOFT.

Always use implements that are softer than the carb body. I'm a big fan of sharpened bamboo barbecue skewers and nylon brush bristles.

Remember that in order to remove Mikuni butterflies, the backsides of the screws need to be filed off, because they were staked to prevent loosening. Failure to do this will result in damage to the throttle shafts. The screws will need to be replaced.

If you're not planning on replacing the throttle shaft seals right away, then DO NOT submerge the carbs or you will be.

DO NO HARM or you ain't seen expensive yet...

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Okey, No "hooning" of the slide shaft.
Luckily the scratches where more or less just "color changes", couldn't feel them and the slides works flawlessly.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

empty for no reason.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

empty for no reason.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

Pilot Air Jet : #170 (#170 XJ550 Seca models)
Main Jet : #120 (#112.5 XJ550 all models)
Pilot Jet : #40 (#35 XJ550)

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleaning)

empty for no reason.

 

Re: XJ550 Euro, Cafe Styled-Project. (Current : Carb Cleanin

Hi, just wanted to say hi to another Swede!

What is your goal with the XJ? Original?

//Bjomag

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