82 XJ650 Cafe Build

Yeah the stock fuse panel was replaced with a 30 amp circuit breaker..... Would that cause the issue?

 

Most likely. The circuits need to be separate and have the right value fuse/breaker or you'll have damaged components and burnt wires.

 

It's even more complex than that.

The stock fuse box APPEARS to simply be four straight-through fused circuits. Ain't so.

The "main" circuit is the FEED for the other circuits; their "hot" sides all originate somewhere else in the harness but are supplied from the main.

So the original fuse box is more like the breaker box in your house, the "main" comes in and feeds everything, and each of the individual circuits has its own breaker (or fuse.) Except in this case they all lay there next to each other looking alike.

This is why you need BOTH the circuit and wiring diagrams before you start modding/rewiring. It's NOT what it appears to be. Plus Yamaha has a habit of locating things "conveniently" like putting all the diodes together in one block in the headlight, when electrically, they are parts of other different circuits all over the bike.

I'd refrain from powering it up in its current configuration, you stand a good chance of cooking your TCI unit or other critical, high-dollar components.

 

What would you recommend I do then with the current setup having the circuit breaker? This wiring stuff is over my head so I'm lost lol

 

UNDO it.

Get ahold of both the WIRING and CIRCUIT diagrams (they're different) for your bike and undo your boo-boo. You'll need a multimeter. Add one to your toolbox, now that you've reinforced the need.

Replace the stock fuse block with a blade-type fuse block of the same configuration. XJ4Ever has "kits" and wire loom extensions, etc.

And quite honestly, if "this wiring stuff is over your head" then DON'T TRY TO RE-ENGINEER THE ELECTRICS. Fix, refurbish, repair-- sure; don't modify until you know what you're doing or you're gonna fry stuff if you haven't already.

 

Hey guys, haven't had a lot of shop time to try and trace down the wiring bug.... had another question though. I want to update my master cylinder and clutch perch.... was wondering what specifications I need to look for in the master cylinder or if anyone knows off the top of their head which bikes I could try to find a used set off? I'd like to switch to a remote reservoir on the master cylinder.
Thanks!

 

Got the wiring issue resolved today! No more lights and starting up without the ignition switch turned on. However when I put gas in the tank it starting pouring out from the carbs everywhere! Pulling them back off to check my floats. When I had the carbs apart I didn't have the float pins so I improvised with cotter pins, bad idea and it bit me. I have a donor set of float pins to replace them with now. Doh!

 

So I got to the shop after a week and a half today and found some rats had decided to snack on my exhaust wrap..... so I guess I'll be doing that over again!


Decided to get crazy with a wire wheel, cleaned up my forks pretty nice and started on my motor but I have to get a smaller wheel to get into the smaller nooks and crannies better.
Before and after:

Started on the motor:

With the cold weather moving in for winter I'm starting to think about just tearing the whole bike back apart and painting the frame and powdercoating some parts to really clean it up.

 

Well I got this far yesterday before running out of time

So close! Couldn't quite get it out of the frame though, going to have to remove the oil filter to be able to get it out I believe.
On a side note, aren't all 1982 USA Models supposed to have YICS?

 

1982 model-year 650 Maxims, yes. You probably have an '81 M/Y bike, titled as an '82.

You can "reverse engineer" your VIN here: http://xjbikes.com/Forums/viewtopic/t=14577.html

 

according to my book, 5N8 will be '82 M/Y 650 Max. & 4H7 or 4W5 would be '80-'81 M/Y.

Fitz is right it's likely to be an '81, seems a lot of US bikes weren't registered in the same year they were built for some reason. :?

 

Good progress colehole. I've been doing something very similar today.

 

Got finished up today stripping it down.... I was now able to get to those center stand mounts to chop them off.


In the next week or so I'll be taking some Simple Green to the frame and motor to get all the grime off and then taking a wire wheel to the motor and carbs. I plan on painting the carb tops and the valve cover on the motor black. I wanted to powder coat my frame but I'm not sure if I'll be able to fit that in my budget so I'm looking into using chassis paint instead on it..... I've heard it's pretty durable and comparable to powder coat.
Also, I researched my VIN a little and turns out it is an 81!

 

man when i took a quick look at the tank... I thought it was a see through tank and I started flipping out LOL.
it took me a while of tying to figure out what it was to realize it was a chrome reflection..

 

Lol yeah just chrome.... Not exactly sure what kind of tank it is but I think it's an old BSA tank

 

Making sloooooow progress, can't find enough shop time. Started prepping for powder coat today. This stuff is amazing and feels great when it gets flicked on your face while using a wire brush.

 

I've been MIA for a little while! Progress was very slow for a little while but I've been pretty busy the last couple of weeks on the bike. So busy in fact I haven't really even taken pictures while in progress. I have sandblasted and powdercoated most of my parts now.


I've still got to blast my frame and swing arm and then I'll be powdercoating them as well. I removed my valve cover off my motor and blasted and powdered it as well and it came out so good I'd really like to remove the jugs and side covers off my motor to do them as well. I was wondering how involved the process is to take off the top end? I've only removed a top end once on a 72 Yamaha R5 and it didn't have cams and all that so I've never messed with all of that....

 

Curious what size gaiters you went with? Nice build as well.

 

Thanks! I went with these gaiters

 

I've been searching around, does anyone know of the top of their head if there's a thread on here with a detailed look at taking apart the top end and putting it back together? More so the putting it back together.... I'm really wanting to pull my top end off to sandblast and powder coat so I don't have a turd of a motor sitting in a shiny powder coated frame with fresh paint and powder coat on the rest of the bike.