Current state of my 82 XJ 650 Maxim Rebuild

A little history. I bought the bike in 2007 and it was my first. Ran great, started reliably and I drove it for a couple of years doing minimum maintenance (oil changes, winterizing). Then the plastic starter button broke in half, and I didn't know how to get it started. So it sat for a year until I tracked down a new starter button (a metal one this time).

Then, I went to graduate school, and it sat again for a year. When I finally got back to it, now it wouldn't start. It clicked when I pressed the button but nothing else. I was going to rebuild the starter motor, and I have a kit for it, but there was also a used starter on ebay for the same price, so I bought both the kit and new to me starter motor. Put the new starter motor in and it cranks the engine. I actually got it to start when it was extremely cold here in Iowa using starter fluid. I decided it was probably time to clean the carbs and do a little maintenance. Also, the cover on the cylinder head was leaking oil.

Currently, I have the carbs off and broken apart. They are taking turns soaking in the carb dip and I scrubbed what I could with a gentle scotch-brite pad and carb cleaner spray. I soaked all the jets for 24 hours and everything has been blown out with compressed air. I will be changing the throttle shaft seals and shims and o-rings on the fuel pipes.

I promise I will do a bench sync.

I promise I will check my float levels.

I promise I will sync the carbs when I get them back on the bike. I know I need to blank the YICS. I have the tool.

I have no idea what color-tuning is. I haven't done any research on that. If you have a handy guide on wth that is, I would be more than happy to look at it. I am planning on doing this, once I figure out what it really is.

I have measured the valve clearances and ordered new shims to get them in spec.

I have a new gasket and new pressure washers for the valve cover.

The front wheel is locked up, and I haven't investigated it at all, but I do plan on rebuilding the front brakes as well.

After reading about how I shouldn't trust the back brakes, I will be taking a look at its condition and re-do it if necessary.

Is there anything that I am missing?

Also, I just want to say thank you to everyone on this forum. I have found your guides and advice to be extremely helpful.

 

Things I forgot to mention.

The intake rubbers were very cracked and looked like they might leak air, so I replaced all 4 of them.

I also rebuilt the fuel petcock and bought a new fuel line and vacuum line. It was leaking gas. The previous owner had installed an aftermarket fuel shutoff valve to fix this. I'm considering putting that back on.

 

Don't forget about the tires.

 

The tires look good based on a visual inspection. I don't know what else I should do/be thinking about with them.

 

dz, welcome back. Check the seal on the gas cap. If it's cracked you should consider a rebuild. The tires are date coded. Anything over 5 years should be replaced. They also have tire wear indicators in tread and "twi" marked on the side of the them. If the tread is worn to these marks replace them. Hope this helps.

 

Well...they're definitely over 5 years because I've never replaced them and I've had the bike for 7 years. Will check the gas cap tomorrow. Thank you!