81 XJ650 build (Project: Jodie)

So i got bit by the bug and decided to pick up this bike with the intent to use the fall/winter to mod it into a cafe racer. Bike runs with a boost, so it needs a new battery. It had been sitting in the seller's garage for quite some time, so safe to say the carbs need to be cleaned at minimum.

I have been searching through the threads on this forum for the last week and have seen a lot of good information. I am a total newbie to this, so bear with me. Its going to be a huge learning curve for me. Hoping to do most of the work myself and may tap the help of a professional, if need be. Anyways thanks for looking and please feel free to post some general advice. I will be posting progress pics as it comes along, however slow that may be.

 

Re: 81 XJ650 build

welcome to the site , lots of great information and help available. just remember do the brakes first more important to stop than it is to go .
Also if you put the year and size of your bike into your signature it can really make it much easier for those helping you out along the way

check out these threads :
http://xjbikes.com/Forums/viewtopic/t=15874.html
and for the valves ; gotta make sure the valve clearances are in spec before you can really sync the carbs
http://xjbikes.com/Forums/viewtopic/t=1 ... rhead.html

good luck !

 

Re: 81 XJ650 build

Thanks for the kind comments and information Devastruction. I will be sure to look into the threads you linked me to. Much appreciated.

 

Re: 81 XJ650 build

Hey, any progress? I've got the same bike (well, '82), and would love to see how it's coming along.

 

Re: 81 XJ650 build

Unfortunately, not much movement as of late. As a govt employee I was furloughed and that has put the project on hold financially. I'll have to watch for your build to see how it's coming along. Maybe you'll have some tips for me in hindsight. Thanks for looking/asking.


This is how it is sitting at the moment:

 

Re: 81 XJ650 build

Well almost a year later and Ive finally gotten around to working on her. So far, Ive stripped her completely down. I have learned alot from the forums and have learned the hard way just trying to figure out things. I am doing mostly aesthetic while i figure out how to do the important upgrades/syncs/maintenance. So far ive done the following:

I pulled the carbs and inspected them. As I suspected, they were gummed up. Also looks like the PO made an attempt at cleaning them, as one of the pilot jet screws were chipped and the carb boot on #3 was incorrectly installed. There was a white residue in the carb bowl, running lean condition?

I am having issues getting the main jet on #4 and the pilot jet screws off on #1 and #2. Looks like they are stripped beyond hope. Any suggestions besides my bright idea to drill thru the screws.

Either way I'll need to purchase new gaskets and jets (came across the sigma 6 jet kit, if anyone wants to chime in on whether its worth the money).

I've checked the brakes, both front and back. The rear brake pads were not delaminated but do need to be replaced.

Ive cleaned and sanded the engine. Not much into chrome, so polishing wasn't an option. So I went with a paint job. It came out better than expected, being this was my first paint job on a motor.

Next up on the line up is painting the rims and gas tank, replacing the brakes, ordering the jet kit and my biggest dilemma is what to do for a seat. I keep tossing back and forth between a brat and standard cafe racer seat setup. I like the brat style, however the slope on the rear of the frame makes it hard fitment wise, at least in my mind. Any suggestions for those of you who've fit a brat seat would be appreciated. As of now I was thinking of getting one long enough so that it sits on the base of the tank (where it screws to the frame) across to the rear of the frame after it slopes up. But this leaves about an inch gap for most of the seat in the center. Will a 16 gauge aluminum base plate hold up my weight of 175 lbs?

Anyways, pics below on the progress so far. I hope to keep updating as I go. Sorry for the wait!

Purchased a xj750R seca tank. It either does not fit directly onto the frame as I researched it would or I was sold a different model tank. Looks like it'll go back up for auction. The stock tank is growing on me.


Carbs off!


Closeup of disassemble


Rear wheel is off. Boy was that a bad idea. I had to fit it back on and wedge the wheel against the frame, just to get the bolts off the shaft on the engine side


Engine out the frame. Took off most of the bolts, laid it on its side and got the last bolts off. Did some shaking and it came right out. Note to others: remember to disconnect the wiring harness prior to shaking motor out frame.



Engine primed and ready for paint, after cleaning with some simple green, a scrub pad, and a steel brush.


Painted it gloss black and aluminum silver. Spray can states to wait 7 days for it to cure prior to painting another coat, if you are outside the 1 hour window. Meanwhile i'll debate on sanding down the fins before applying a clear coat. Waiting game it is.



Frame was sanded down and removed some surface rust. Then painted a satin black.


Thanks for looking. Hopefully, I'll post some more soon.

 

Holy smokes, looking good!

 

Looks like an '83 550 Seca tank on there.

 

Thanks PilotSmack!!

That would make sense as to why it isn't a direct fit. Thanks for the info.

 

As long as your there take the swingarm off and treat it to new grease.
The top front of the swingarm gets chipped up, maybe a extra coat of paint.
Stand the frame up on its tail, see if any water is in there, there might be some real nasty stuff in there, caution.
In the cavity where the swingarm bolts are there should be a little hole on the bottom to let any water drain, keep those clear.

 

Some excellent tips. Thanks for the insight!

 

Re: 81 XJ650 build

I have sigma6 jets on mine, and I'm quite pleased with the results. The directions were intimidating as all hell for someone who had never seen the inside of a carburetor before, but I got through it with a little help.

Oh god. Please tell us that's heat resistant engine enamel/primer. Either way, it looks great (for now at least).

I see you're unmarried. :lol:

Looking forward to it, and welcome!

 

Re: 81 XJ650 build

Guess I'll have to check out that jet kit.

And yes of course. Duplicolor engine enamel primer and paint. Rated for 500 degrees.

Good guess on no wife. No other way there would be a motor dead center of my living room lol

 

Where in my are you? I'm just south of Utica.
If the tank is real good, I may consider trading you that one for a 750 maxim tank...... Which is what you reAlly wanted--- I have few of them.

Pm me!

Dave Fox

 

Sorry Dave. I posted it up for sale last night and it sold by the morning. It's already on it's way to the buyer.

 

Baldwonder are you running pods with the sigma jets? And have u had a lean running issue yet ?

 

Two-yr old thread.......OP hasn't been on the site since December 2014, either........

 

@Steven P : Aye, I'm running pods with the sigma jets. No lean issues yet. Sigma has you widen a lot of holes during installation, so more gas gets in too.