xj650 brat/tracker

What do you guys think of my build so far?

 

Looks good.

 

so far so good!

 

I like it...great start.

 

loose the engine guards

 

Agree with @Polock - If you're trimming the fat, the "love handles" should go under the knife too!

 

Better yet, make a set of case guards that look more like this.

 

Seat looks great!

 

thanks guys, for the advice. I worked on her some more this weekend and got the tank and the fenders primed. Just need to touch up a few bondo spots and wet sand. I want to go with a white tank and black fenders to minimize them. semi gloss possibly or mate paint and a semi gloss 2k clear.

I plan on using the motogadget m-unit to reduce wire clutter and ditch the relays and fuse box.

I do have questions on some of the wires coming out of the motor eg the 3 white wires coming out of the alternator. One of the wires go to the diode block. If it don't run it to anything will there be issues with the electronics?


If your opinion would it be sleeker to convert all the wiring to weather proof bullet connectors or use the delphi weatherproof connectors? Since i removed the air box i want to keep the wires as minimal as possible but keep all the safety features

I am also torn if i should do an oil catch/breather or just a filter any recommendations?

 

The voltage from the white wire is rectified by the diode within the diode block and applied to the head light relay. When the bike starts and the AC Generator outputs a voltage it energizes the head light relay, turning the head light on which is then latched by the relay. If you are getting rid of the head light relay and using the motogadget features for the headlight you will not need the wire.

I did a quick look at the motogadget wiring and will admit to being very unfamiliar with it. I see a provision for the side stand switch, but not for the clutch or neutral switch to provide the safety interlock that allows the engagement of the starter only in safe conditions... in neutral or in gear with clutch pulled in and the side stand up.

 

I found this diagram online that i am going to use as a template for the m-unit . The neutral and clutch cut off and kill seem straight forward. I know its not the same parts but its a start.

I'll draw up a new diagram in case others want it.

 

I found this diagram online that i am going to use as a templat

Those are next to come off!

 

I tried to edit the first post to include more images but its seems i cant ;(. So here i go!

the build started in March 2015 with me just tuning the motor and checking the valve shims. I then decided while she is already apart to redo the fork seals which was a pain in the butt getting the bottom race in.





Then when it got warmer outside i decided to weld on a frame hoop and start tearing into her more.

 

After the seat was final I went ahead and started figuring out how the seat would get mounted down. The idea was two thumb screws and a side cover fastener tab relocated to the center of the frame hoop tail. That way the tail would pop into place and the two thumb screws would hold it down in the middle I then cut the cone shaped knob off the side cover and fiber glassed it to the bottom of the seat. I can take better pics of it if people want.

 

Next was making the rear fender... I decided to buy another rear fender and weld them together to make a whole new single piece and it worked!

 

I was so proud of the fender. The test fit was spot on and then i tried the seat... Never the less It had to be cut.

You can see the seats mounting tabs I mentioned in the earlier post and I also welded in a pan, battery box and relocated the ignition.

I also found a place for the solenoid.

 

My seat arrived and here she is from the rear and side. In the photos the seat isnt mounted. its just sitting on
top, so it looks a little off.

Right before the seat cam i noticed the inside of my tank getting rusty so i treated it with mauratic acid, gas rinse, degreaser followed by acetone and por-15 tank sealer. The tank was completely dry and clean.

The por-15 didnt take and dislodge from the side of the tank when it dried. If you looked in the gas hole you saw a deflated tank. It took me 5 hours to get it out of my tank. What came out blew my mind. it looked liked Styrofoam.
I ended up using red kote for the second try and im happy with it. Just wish it wasn't red.

 

Good work man! I am digging that setup!
Did you sew up that seat or ?

 

All I did was the pan and the cushion. The leather was done by an upholster in Baltimore. Pricey but worth it.

 

The upholstery looks deadly

 

thanks man, the stitch work was done by bens auto glass near Baltimore. They do awesome work and are always busy restoring upholstery in old classic cars.

The bike looks totally different now i'll try to post some photos this weekend.

 

i wanted to give everyone an update on the bike. I am proud to say that i have officially finished working on the bike (for now ) and she rides like a dream.

I ended up with 3" harley exhaust on the bike that sounds badass. I linked a video below that shows off the sounds. I might have to look into the typical motor whine one day.

To list what i did and the parts i used:

• Motogadget m-unit
• Motogadget button
• seca 650 tank
• custom fabricated seat
• Magazi round mirrors
• no School Choppers 1933 - 1936 Ford Blacked Out Tail Light & bracket
• 3800 Lumen H4 LED Headlight bulb cyclopsadventuresports.com
• Koso TNT speed and tach
• custom Battery box
• anti gravity 8 cell battery
• Progressive springs in the front
• custom rear fender (+ paint)
  
• chopped front fender (+paint)
• frame loop
• new seat brakets.
• Uni Pods
• signals (i forgot from where)
• various raw metal @ brackets from tcbros and lowbrow
• sigma 6 dyno kit
• arlen ness foot pegs front and rear

Via Len (chacal)

• clutch plates & springs + gasket
  
• fork seals
• steering stem bearings
• carb rebuild kit
• valve cover gaskets & bolts +_ bumbers/bushings
• valve shims
• clutch switch & perch
• starter rebuild kit

I would also like to thank the community here as if it wasnt for them i probably would have given up. k-moe, hogfiddles. chacal, bigfitz and you know the rest.
A special thanks goes out to jayrodoh for helping me wire up the m-unit!

 

Looks ans sounds great! Nice work!

 

I just bought the motogadget m-unit and would love to see a diagram you came up with for the xj650. Thanks in advance.

 

Most of the connections are straight to and from the m-unit, what ever you do, do not connect the tci to the unit. You will blow out the m-unit. It would be cool if it did control it but nope!

I'll draw something up tonight as a guide.

 

I would like to see your drawing too. I'm very interested in the m-unit for my basically stock 82 maxim 750. I went to LED lights/flasher so I lost the self cancelling function. Also the safety relay system was eliminated by the PO. The clutch switch is gone but I did replace the side stand switch. Now I have the Atari working properly. Will the m-unit affect the Atari function?

 

I was wondering about the tci...thanks so much. Looking forward to seeing it.

How do you like it so far?

 

I checked my notes and i was wrong you do connect it to the TCI. The part i was trying to warn about is do not... connect the aux line out to the starter solenoide. It will draw too much and burn out the aux port.

I do love it. I just wish i got their hand controls.

See below.

I cant take full credit for this. I had help from jayrodoh and used the xj650 minimal wire diagram (green bg)

 

I also want to add that there are many different ways to wire it. And this is just one way to do it with minimal relays and keeping all of the saftey options.

 

Thank you for sharing this, and to those that came before you and their help. This is the biggest reason why I love this site. Like minded enthusiasts helping each other. You rock! I don't have the m button for my hand switches...been thinking of getting it.

 

Definitely post up or PM me if you have some questions. I love electronics and bikes. You're only a few hours from me, will have to meet up this summer once we get these things on the road!

 

Most definitely

 

This is my girl...budget build until I bought the motogadget m-unit...lol

 

Nice

 

Very cool digging the colors and the shape of the tank. Love the minimal look at the headlighy

 

I think I'm going to have some questions for you about the TCI unit early next week sybe...I got the taillight and rear turn signals wired up today. Moving slow, but want it done right.

 

Thanks sybe...the tank is off an xj700...making a tank strap to ensure is stays secure.

 

Ask away, I'll do my best to help. Slow and steady wins the race!

 

Hey dude - bike looks great - I recognize those grips and that tail-light I really want to make a seat like that for mine!

Any tips / tricks on using that carbon fiber would be appreciated. Do you have any issue with clearance as you lowered the gap for the rear wheel?

Who did you get to do that upholstery in Baltimore?

 

Thanks man. The shop i used for the stitching is bens auto glass. They were pricey at $350, but the stitching work is awesome. You might be able to find someone cheaper.

The clearance in the rear is fine. I tested it out by having my stepdad sit on the seat with me. I also hopped up and down on the seat to simulate bumps and all was good.

I can put a tutorial together on how i made the seat pan and what i used for the padding. Might take me a day or two.

Are you looking to install a frame hoop for the seat or keep it stock?

 

Thanks dude - that would be great.

I plan on adding a frame hop - but I'm also toying with keeping the frame stock in the back besides this and make the seat with a rear hump. Should be the same concept/process though.

 

The hardest part is figuring out what you want and how to mount it to the bike. If you keep the stock airbox in place you will be limited, but there are solutions. Welding is a must.

 

Yeah, I have a pretty good idea of how I'm going to do it now. I actually haven't done any welding before - well not since high school that is - and i don't have the gear so I just need to figure out what I need to have done and pay/barter someone to do it for me. I'm hoping the only thing I'll need is the frame hoop - once I get that sorted I can make the base for the seat like you did with the fiberglass. Did you post that tutorial somewhere? No rush if not, just wondering.

 

Haven't had time to do a write up yet. Been swamped with stuff with the wife and work. I'll try to do one asap.

 

In between time enjoying my 2 month old son, i managed to get my bike running with no issues. I went with oem gaskets just to make sure fitment was perfect. During the rebuild, i decided to relap the valves again and replace the stem seals with oem and recleaned the pistons. Ac delco aka... Genuine GM Fluid 1052626 Upper Engine Cleaner removes carbon like melted butter. 2 + 2 gum cutter is awesome too. When reinspecting piston 3 and 4 i noticed i missed some carbon which was causing the rings to stick. Sprayed some cleaner and cleaned it off with a toothbrush and wham-oh. No more burning oil.

I also managed to rework my seat a bit. The thumb screws i used would fall off while riding, so i had to rethink a new way to lock the seat. 1/4 Turn Quick Release Race Fairing Fasteners plus resin was my solution. It works better than the shoulder screws.

Took her out for a spin on friday, colortuned and she is purring.

I did notice a flat spot in my rpm range that might be due to using a baffle and packing my mufflers. The jets i am using are stage 2 for the pods and the open mufflers. I know i know airbox is better. I was thinking of switching to a mikuni but wasnt sure if it would work. Mikuni bs33 is what i was eyeing. What do you guys think?

Battery doesnt seem to be charging so i plan to tackle it next. Might just buy a core and rectifier off ebay. If i wanted to upgrade the charging circuit to allow for more power, is it even possible?

 

I am finally done... for now anyway. Enjoying riding her around brooklyn, few odds and end needs tweaking. All in all she is riding great.

 

Hey mate I'm currently wiring in a m unit blue
Where does the two brown wires go that come from the regulator and out of the ac unit? Do these two wires get spliced together then ran to a constant or switched power like AUX? thanks

 

threads is a little old
wiring diagram shows 1 wire from voltage regulator and another from alt. both go to off and join up to fuse block and key