1982 Maxim 550 Chopper Project

So I bought a 1982 550 maxim for a project bike. After replacing the intake boots, cleaning the carbs and replacing both coils we were able to get it running well enought to move onto the hardtail part of the project as planned. It is pretty rough looking and will need lots of elbow grease to get it looking decent again. This will be my first build but my next door neighbor has done a few that turned out very nice.



Its always nice to have the PO give you a rubbermaid full of parts. Too bad these were not extra but just ones that had been removed. Will post more pictures soon as we have already done quite a bit.

 

Are you going to eliminate the triple backbone? How much rake and stretch are you going to add?

 

I think we are going to stretch the bottom tubes about 6 inches. For the back bone I'm going to cut at the 3way area, if that makes sense, and put a piece of 1.5 inch tube over the large tube that is already there. It will run from the neck down to I'm not sure how far yet.
Here are some more pictures:


That one is with no electrical. I'm going to rewire the whole bike using a simplified wire harness I found on this forum.

Now we are down to a roller

 

I wasn't sure how many pictures could go in one post so here are the rest:





So I'm hoping to have a roller again by the end of the week. We got the axle brackets welded into the bottom tubes and attached to the rear wheel. Now we just have to attach them to the front half of the frame and figure out the new top tube/backbone. I'm using the TC Brothers universal hardtail kit and it seem to be good stuff so far.
If anybody out there has any tips or suggestions I'm open to advice as this is my first build.

 

A rolling frame is cool, but how are you going to mount the motor? You cut the frame just ahead of the rear motor mounts (the ones that matter) so all that's left are the front mounts which it pretty much "hangs" from.

 

Oops!

 

I know you said your neighbour has done a few builds before, but did you mean the same as yours? Cutting the bike in half and then putting them back together is a pretty adventurous project. Do you have some kind of jig to align the two halves back together or you just going to "eyeball" it? If things are out of alignment when re-assembled you may have a bunch of problems with wheel alignment, engine alignment etc.
Good luck and keep us posted.

 

what are your plans for the seat?
I see it's in pretty good shape... mine not so much...
so if you plan on cutting it up maybe we can swap...

 

CHAIN alignment, between the front sprocket and the rear...

The rear motor mounts on the 550 are the main motor mounts, the fronts just kind of "hang it" in position. The rear mounts are the "anchor" point for the engine/transmission, and also what keep the forces trying to pull the engine and rear wheel together (the torque applied to the drive chain) at bay.

Whatever frame is constructed from what's left, the size, configuration and most importantly position of the rear motor mounts are paramount. By cutting the frame where it was, some SERIOUSLY careful fabrication will be required; or we're looking at another parts bike.

 

I think you had better go to the Chopper Handbook and do some reading on the proper way to build a motorcycle frame.

 

Hey JUNK8, I saw something on another forum that relates "sorta" to what you are doing. It's a pic of a jig that a guy built when modifying his bike. Before he cut anything apart he measured everything and then put the bike in the jig before he started. I know it's a V-Twin in the pic but the guy will be able to put everything back in a straight line front to back and side to side when he puts it back together.

 

Oops, forgot. If you want to see how much work the guy did then go to
http://www.caferacer.net/forum.html
and put
own buid.. virago750
in search under project builds. The author is virago82

 

RookieRider I sent you a PM. The seat is yours. I'm going to make one myself or pick up an inexspensive used one.

Thanks for the input everybody and yes I am very aware of chain alignment. The last thing I want is it running at an angle causing it to break and slap me in the leg or head. On the scale of 0 to suck that would suck. We took measurements and used clamps and squares and more measurements to get everything as straight as possible without having a professional frame jig. All measurements were within 1/16th of an inch as I thought that was within tollerances for me.

I realize that I cut the rear motor mounts off and that they were crucial on the original frame but I wanted a clean look along the bottom. New rear motor mounts will be fabricated and checked for square so the sprokets line up properly. I don't want this thing coming apart at 60MPH with me on it.

 

Here are some more pictures of this afternoons progress




I hope I haven't offended anybody by cutting the ol' bike in half. Some seemed like they didn't like it. Thanks for the link to Chopper handbook. There is lots of info there to help out. No my neighbor has not ever chopped a Maxim before but has done about the same thing to Honda's, Kawasaki's and Harley's in the past. I trust him that he knows what he is doing to guide me along on this project. Plus he is going to be the one to come pick me up if I break down. Oh and don't worry the '85 Virago in the backgroud of some of my pictures is staying stock. Keep the suggestions and advice coming.

Sam

 

Here is a link to another member's 550 project. It might give you an idea on how to do the new backbone.

550 hardtail

 

How much ground clearance are you going to end up with? The XJ motor hangs down between the frame rails quite a ways, you don't want to be dragging the sump.

It looks like it might be sitting a tad low.

 

fitz is right it does look pretty low.. i know my bike is low with like just over an inch of clearance, might want to check that. other than that it looks good

 

The build looks awesome man, i'm really wishing i had scored on the 550 like you and tuba but thats life i guess. can't wait to so both of these finished.

 

The angle does look pretty low but it is just the angle of the pictures. Up front it is about 7 inches at the bend and in the back at the bend just in front of the axle plate it is 5 inches. I think if anything is going to drag it will ne the exhaust collector but I'm not sure if that is going to go back on or make a 2 into 1 on each side without the collector. No real big progress the last few days, just cleaning the frame up. Waiting on more parts to move on to the next steps.

Anybody have any advice on painting an engine. I'm going to use engine enamel in semi-gloss black. What is the best way to get the engine clean? I used one can of GUNK already and it did OK but there is some 30 year old dirt that wants to stay put.

 

Eagle makes a mag wheel cleaner that actually does well in small doses on aluminum. If you use it, do one spray at a time and do not let it sit. Plug up the ports and hose it off regularly... It can be brutal if left on too long. I was going to cap my ports and try a pressure washer, then move on to the mag cleaner.

 

Don't use a pressure washer. You can drive water IN past seals that were only meant to keep oil in, not water OUT. And end up with water in your transmission or middle gear case.

 

So the build has been on hold for the last month since i broke my leg/ankle at the end of December. I have only been able to work inside for the most part and not in the garage. I have managed to paint the tank when the weather was warm enough. It still needs a few coats of clear. Mostly working on my leather seat which is the first one i have ever done. I will post a picture in a few minutes. I think it turned out pretty good for a first attempt. Only 1 more month in a cast before i can walk again and then start putting everything back together.

 

here is the picture of the seat

 

Damn dude... did you tool that yourself? That's friggin awesome for a first timer.

 

So the build is now done. It took a little longer than planned but but with a broken leg, a wife and 3 kids, full time military and other projects popping up it is finnally done...well sort of. Still working on intake issues and exhaust but it runs and stops. I'm thinking dual 2 into 1 intakes and exhausts. It sounds pretty awesome but i don't want to upset all the neighbors. Here are a few pictures.

 

Id say its come up pretty good.
Would like to see some ape hangers on it.

 

Bike looks badass!

Personally, I'd look for smaller gauges to clean up the look a bit but other than that, bike looks mint!