New Guy In Town.

Good morning ladies and gentlemen, name’s Nick and I’m out of Vegas. I purchased an ‘82 XJ750 a little while back and I’ve been lurking here trying to learn thing or two about her until I posted and exposed my ignorance. I’m fairly new to riding and wrenching on bikes and it has been a steep learning process. The good thing is I’m fairly mechanically inclined and was able to practice my skills on my girlfriend’s ’88 XV250. Now I’m moving on to my XJ which is a little worse for wear. I have a few questions and I’m hoping someone here doesn’t mind wading through this wall of text and answering a few questions.

Right now the bike runs somewhat but isn’t even close to road ready. Unfortunately she will only idle/run at full choke, the fuse box was eliminated and the wires spliced together (see attached pic at bottom) and she is down to the metal on the front pads. Also, I have noticed the exhaust collector is quite rusted with some small holes showing. I have all the manuals and I intend on going through the entire maintenance section to diagnose any other issues and ensure she is in tip top shape. Obviously from my idle/choke issues this will entail a full carb rebuild and I intend on a full front and rear brake job. To this end I am trying to gather all the tools and parts I am most likely going to need to limit her downtime.

So my to get to the point, I have three main questions; would anyone be willing to go through my included parts list and point out any discrepancies and any missing or superfluous items, does anyone know where I can obtain an exhaust collector in decent shape aside from installing an aftermarket exhaust and what are “end cap seals”? They were listed in the required parts in The Church of Clean thread but I was unable to locate them on Chacal’s parts list.

I also wanted to express my gratitude for the riders who have posted the vast amounts of knowledge on this forum, it has already been invaluable and has made me feel like this project will only be moderately impossible instead of ridiculously.

Thanks in advance guys!
Nick



Carb Rebuild:
HCP54SET4 Aftermarket Hitachi allen-head stainless-steel carb BOWL DRAIN SCREWS, set of 4:
$ 17.95

HCP895SET4 Aftermarket Hitachi idle mixture screw O-RINGS, set of 4:
$ 4.95

HCP896SET4 Aftermarket Hitachi idle mixture screw spring seat WASHERS, set of 4:
$ 5.95

HCP1SET4 Aftermarket Hitachi carb LOWER END STANDARD REBUILD KITS, set of 4:
$ 69.00

HCP2420SET6 Aftermarket Hitachi Viton material fuel supply tube O-RINGS, set of 6:
$ 6.95

HCP38BSET8 Aftermarket Hitachi throttle shaft V-SEALS, set of 8:
$ 28.95

HCP1349SET8 aftermarket Hitachi butterfly valve retaining SCREWS, low-profile hex-drive allen-head screw made from 18-8 stainless steel, set of 8:
$ 10.00

Misc Parts:
HCP4689SET4 OEM cylinder YICS PASSAGE O-RINGS, set of 4:
$ 22.95

HCP4430 OEM left side HANDLEBAR GRIP ASSEMBLY. Fits all XJ650 Turbo models, all XJ750 Maxim and Midnight Maxim models, and all 1981 XJ750 Seca models through frame number 002949.
$ 19.95

HCP4431 OEM right side HANDLEBAR GRIP ASSEMBLY, includes the throttle tube. Fits all XJ650 Turbo models, all XJ750 Maxim and Midnight Maxim models, and all 1981 XJ750 Seca models through frame number 002949.
$ 26.95

HCP998SET2 OEM oil pump covers or "YICS" covers paper GASKETS, set of 2:
$ 12.50

HCP7153LF Replacement FUSEBOX, 6-circuit with a full set of glow-when-blown indicator style ATC push-in style fuses (4 x 10A, and 2 x 30A), for all XJ750 Seca, 1982 XJ750 Maxim, and XJ900RK models.
$ 16.00

HCP1621 reproduction valve cover hold-down bolt rubber PRESSURE WASHER, used on all XJ550 models, 1982-84 XJ650 Maxim models, all XJ700 non-X models, and all XJ750 models. These washers are for the four INNER bolts. HCP1621SET4 reproduction valve cover hold-down bolt rubber PRESSURE WASHERS, set of 4:
$ 8.95

HCP1622 reproduction valve cover hold-down bolt rubber PRESSURE WASHER, used on all XJ550 models, 1982-84 XJ650 Maxim models, all XJ700 non-X models, and all XJ750 models. These washers are for the eight OUTER bolts. HCP1622SET8 reproduction valve cover hold-down bolt rubber PRESSURE WASHERS, set of 8:
$ 13.95

HCP1625 Reproduction rubber VALVE COVER GASKET, for all 1982-3 XJ650 Maxim models, all XJ700 non-X, and all XJ750 engines:
$ 34.00

Brakes:
HCP1075SET8 OEM brake hose junction UNION BOLTS, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 8:
$ 14.00

HCP1077SET4 OEM brake hose union bolt copper CRUSH WASHERS, set of 4:
$ 5.75

HCP1077SET12 OEM brake hose union bolt copper CRUSH WASHERS, set of 12:
$ 16.00

HCP1074 Aftermarket front brake master cylinder glass brake fluid level SIGHT WINDOW, correct size and thickness crystal-clear mineral glass. NOTE: Fits all models that have a pressed- and glued-in original sight window. Does NOT fit original master cylinders that have an o-ring and c-clip retained sight window. Each:
$ 5.95

HCP1936SET2 OEM front disc brake CALIPER PISTONS, includes two brand new pistons, piston fluid seals and dust seals. One kit does one caliper. Fits all XJ650 Turbo models and all XJ750 Maxim and Midnight Maxim front calipers. Pair:
$ 99.00

HCP2877CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with clear sheathing. FOR USE WITH ORIGINAL XJ750 MAXIM OEM MASTER CYLINDERS.
$ 47.95

HCP2878CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the right brake caliper, with clear sheathing.
$ 49.95

HCP2879CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with clear sheathing.
$ 49.95

Tools:
HCP1282 Aftermarket YICS chamber PORT CLEAN-OUT TOOL:
$ 14.95

HCP5904 Aftermarket JIS-standards SCREWDRIVER SET. Japanese phillips drive screws have sharper corners than regular phillips screwdrivers so they won't turn out under heavy torque. In order to take advantage of this feature, and to avoid stripping out the JIS screw heads by using US-standard phillips screwdrivers, it's a good idea to invest in a set of quality JIS-standard screwdrivers. This set of 4 contains one each of #1, #2, #3, and #4 sized-tip screwdrivers, and this range of sizes will handle everything down to an M2 sized screw (that's tiny, smaller than the size of the petcock faceplate mounting screws) all the way up to screws bigger than anything I've seen used on these bikes. They all feature sturdy plastic handles, chrome plated steel shafts, and come in a handy vinyl storage pouch.
$ 37.95

HCP247A Aftermarket valve shim BUCKET RETAINER TOOL:
$ 16.95

HCP9997 Aftermarket carb rack re-assembly ALIGNMENT PLATE.
$ 17.95

HCP953 Carb Passages MAN-SIZE CLEANING WIRES TOOL SET contains 22 small wire tip cleaners, sizes #6-45, in a handy aluminum flip-open case.
$ 9.95

HCP2296 Aftermarket BOWL STARTER JET DRILL BIT, for Hitachi carb bowls used on all XJ650 (except Turbo) models, all XJ700 non-X models, and all XJ750 models.
$ 11.95

HCPSS-SET Complete set of nine different 18-8 STAINLESS STEEL WIRE BRISTLE BRUSH (all sizes except the 19.0mm), gives you all the sizes needed to clean your carbs, YICS port, and master cylinder bore (when that time comes).
$ 32.00

HCP1714 o-ring installation pure SILICONE GREASE:
$ 6.95


Not included in this list are parts ordered from BikeBandit; brake pads and shoes, two new rotors, a master cylinder rebuild kit and new tires.

 

Solid list -

as for the collector, just keep an eye out on ebay and for guys parting their bikes out on here.

How handy are you and in what shape is yours in?

I have two spares, one im leeping for when the one on my bike becomes shot, and another one that i had to cut the chrome cover off one side of it. If you have a welder and a cut off wheel, you could without too much effort cut off the chrome guard on yours, and weld it onto the mine. there might be a small hole or two iirc, but if you're there with the welder anyway, those would be easy enough to seal back up.

Just an offer if you wanted to buy it.

Otherwise, keep an eye out on ebay and DONT pay 80 for a piece of garbage like this, lol

http://www.ebay.com/itm/Yamaha-XJ750-Ma ... 23&vxp=mtr

 

Welcome to the forum and good luck with your bike-your in the right place.

 

Welcome to the forum and good luck with your bike-your in the right place.

 

Misc Parts:
HCP4689SET4 OEM cylinder YICS PASSAGE O-RINGS, set of 4:
$ 22.95
have to pull the head for these
-----------------------------------------------------------------------
HCP998SET2 OEM oil pump covers or "YICS" covers paper GASKETS, set of 2:
$ 12.50
no oil under there, you can use RTV gasket stuff
-----------------------------------------------------------------------
HCP1936SET2 OEM front disc brake CALIPER PISTONS, includes two brand new pistons, piston fluid seals and dust seals. One kit does one caliper. Fits all XJ650 Turbo models and all XJ750 Maxim and Midnight Maxim front calipers. Pair:
$ 99.00
yours might not be bad
-----------------------------------------------------------------------
HCP247A Aftermarket valve shim BUCKET RETAINER TOOL:
$ 16.95
can use wire tie or copper wire
-----------------------------------------------------------------------
HCP9997 Aftermarket carb rack re-assembly ALIGNMENT PLATE.
$ 17.95
can use anything flat
-----------------------------------------------------------------------
there's a few more things that you don't really need but are nice to have
chacal's going to hate me

 

Thanks for the offer, unfortunately I have no access to welding gear. And in light of all my recent tool and parts purchases I'd likely find myself single should I decide to buy a setup at this time.



Polock, thank you very much for running through the list. I had a question for you if you don't mind.

Do you mean the pistons might not be bad or the seals? The reason I was getting these is because it is the only way to order the proper seals for the 750 Maxim calipers.

I will look into this, thanks for all the advice.

 

Your seals are old and bad, but the pistons might not be rusted. Once you get them out and see what you need, you send Len (chacal) a PM or email and he can fix ya right up.
There is something about maxim seals, don't remember what it was,
Len knows

 

From the catalog:

It would appear that I have no choice but to purchase the pistons as well but I will definitely ensure with Len that this is correct. Thanks for the heads up.