1982 XJ650 Maxim Project

Before:


Here it is the day I got it. It's fairly clean, though there's some rust on the frame and pipes. It ran for a bit, but now it's not. :lol: Carb intake boots are loose and leaking gas and are also probably keeping my bike from starting. These are my main priority, as well as a spark plug hole that I stripped when checking the plugs. While I'm waiting for a spark plug re-thread tool to come in the mail, I'm going to be getting rid of the rust on the pipes and painting them high-temp flat black. A soda can or two might be necessary to cover up a few rust holes in the exhaust. Luckily the pipes are the worst part that I can tell.

Black clubman bars that just came in will be going on as well, and I'd definitely like to swap out the tail-light for some kind of fender eliminator deal. I'm thinking an integrated tail-light. I'm also thinking maybe a more modern style seat. Custom job probably. Though the seat is in such nice condition that I might keep or just sell (anyone interested or know what it's worth?), or I might just chop the back half of it and go from there. I'm new to all of this, so any advice/thoughts on such work would be appreciated. Thanks!

Update 10/22/13:

 

Re: Black XJ650 Project

Painted bars can give you problems with the hand controls since they get their ground thru the bars.
Better use high temp header paint for the pipes or it'll burn right off.
Have you checked all the important things like: valves in spec, brake lines, brake pads and shoes, bearings and tires?
Replace those boots and clean the carbs while your at it.

 

Re: Black XJ650 Project

Na, I haven't checked anything yet besides the obvious stuff like tires and brakes. Back brakes work fine, but the front ones need to be overhauled. It probably does needs a carb clean/jet adjustment, but I'm going to try to get it running again before I do all of that. As for the boots, someone on here told me to try loosening the air box to bring it closer to the boots, which sounds like a good plan to start with. I might also try heating the boots in water to expand them and make them easier to work with.

Just a few minutes ago I finished up the exhaust paint job. I covered up the parts around the pipes and just sprayed 3 coats of VHT from AAP on it. I might want to sand off a few parts and re-do it since some of the paint didn't go on as smoothly as I wanted. I'll see how it looks once everything is dry. Before the pipes, I put on my clubmans and they look great. I'm digging the less chrome look. hahah Now I need new grips because I had to tear apart my left grip to swap the clutch lever to the new bar. It also worked out so that my right-side mirror is actually useful now.

 

Re: Black XJ650 Project

You can't go by that. You need to VISUALLY INSPECT THE SHOES for signs of delamination. READ: http://xjbikes.com/Forums/viewtopic/t=15874.html

Airbox boots don't leak fuel. CARBS leak fuel when they have issues, especially float issues. Issues that can cause them to dump fuel into the motor.

 

Re: Black XJ650 Project

All of the maintenance things aside, that is a beautiful bike. It sure does look to be in great cosmetic condition. Just use the search function for anything you may have questions about. There are a lot of good examples of these bikes as cafe racers and bobbers. I personally like both of those styles over stock, though there are a lot of purists on this forum. Good luck.

 

Re: Black XJ650 Project

Thanks, Proximal. It does look great, which is why I'm having second thoughts on doing too many mods other than what is necessary. I'm thinking this bike will hold it's value better as close to stock as possible. With new bars and the black VHT painted pipes, that's probably about all I'll do to it cosmetically. Now to get it all cleaned and tuned up on the inside... brakes, cables, fluids, re-threading a spark plug hole, possibly a carb rebuild. I'll see how adventurous I'm feeling.

By the way, do you have any pics of your XJ650J?

 

Re: Black XJ650 Project

Check and adjust the valve clearances. SOON.

Then you will need to service the carbs; how much "rebuilding" is required will be determined by what you find in the process.

 

Re: Black XJ650 Project



Progress pic. Painted the pipes and put clubmans on, and I got the bike running smoothly. Need to go through it and check all of the safety things before riding it outside of town though. Cosmetically, I'm thinking a barend mirror to replace my stock mirror which is useless with my current bar set up. The fenders might be getting a gloss black paint job to match the tank. Not sure about it though since the fenders are still so shiny!

 

Re: Black XJ650 Project

Can't just ignore them. You could damage the motor.

 

Turns out one of my main problems was that I removed the crash bars the night I got the bike and never put the bolts back in. Had I known those were crash bars and engine supporting bolts, I'd have left them obviously. Anyway, the engine was sitting about an inch forward, which is why the air intake boots were all yanked off. Another easy fix was the fuel line which the previous owner didn't even have tightly on, which seemed to be the cause of my fuel leak down the side of my engine.

Besides that, I started getting fuel leaking out of my exhaust, which led me to check the air filter which was totally clogged up and smelled of gas. With a brand new filter, the bike runs like a whole new machine. I didn't even realize before how much power these old 650s have! As you may know, it handles the highway no problem at 80-85. I was definitely hitting 100 with more room to go yesterday. What a great bike! Now there is still some popping in my exhaust when I let off the throttle, but I'm hoping that's just gas sitting in there from before and that it will go away.

 

If you are getting popping during deceleration, that is an indication of a lean condition. Check your plugs and see what color they are.

 

After a 50 mile ride, they looked tan without any white build up, so I don't think I'm running too lean. I'll pull them again though since I just put another 40 miles on it. Before the air filter swap they were all black and sooty, with plugs 3/4 wet with gas. Those were on the side with the exhaust popping, if that helps.

 

You better get after the valve clearances and soon; and check your float levels. In a different post, you mentioned oil/gas saturating your air filter.

Popping under decel is generally due to a lean condition; tight valves can also contribute.

You've got something "unhealthy" going on with that motor that you need to investigate before you hurt it.

 

I'm hoping you've checked the rear brake shoes for delamination...imagine what would happen if the rear wheel would lock up at that speed. Would be smart to rebuild the front brakes too ( master cylinder, caliper, pads, and especially new brake lines).

These are major safety issues that shouldn't be ignored...unless you don't care about your life.