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Cafe project...XJ650RJ

Discussion in 'XJ Modifications' started by desmotom, Jul 28, 2016.

  1. desmotom

    desmotom Active Member

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    I have had my bike for over 15 years now, rebuilt it frame up 10 years ago. I haven't started it in 5 years, life got busy and insurance is stupid expensive where I live. I am in the process of going thru the bike before I start my project to be sure everything is working optimal. Pulled carbs so far, and compression check. 125-130 on all 4 cylinders, so I am sure it wont need any internal engine work. Have to check valve clearances yet.

    IMG_1278.JPG

    Plan is to change to café style seat, clip ons, rear sets and a modified fender for now. I want to make changes that can be reversed if one day I want to go back to stock. I started making a new upper triple clamp already and going to start on clip ons and rears sets.
    IMG_1297.JPG
    will try and document all the steps and keep this thread going. maybe a you tube series???

    any input on project would be awesome.

    thanks
     
    desmotom, Jul 28, 2016
    #1
    Jetfixer likes this.
  2. Jetfixer

    Jetfixer Well-Known Member

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    I like it how it is!! Please don't turn it into a bobber , I hate seeing a frame cut up. Like adding a fairing over rear with a modified seat pan ,but keep the bars love the café look.
     
    Jetfixer, Jul 28, 2016
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  3. desmotom

    desmotom Active Member

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    I won't be cutting the frame. No changes I will be making will be permanent...
     
    desmotom, Jul 28, 2016
    #3
  4. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    You have a seriously rare XJ (in the U.S.). Thank you for not doing anything that can't be undone (like cutting the frame).
     
    k-moe, Jul 28, 2016
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    desmotom likes this.
  5. desmotom

    desmotom Active Member

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    image.jpeg image.jpeg image.jpeg image.jpeg image.jpeg Worked on the bike tonight. Got it started but it wouldn't idle. Would only run on enrichment circuit. Went through carbs and everything seemed good.
    Plugs.....

    Feels good to be working on it again!
     
    desmotom, Jul 29, 2016
    #5
  6. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Soot, oil, oil/soot, soot. All rich and two possible valve stem seal leak/ ring leak.
     
    k-moe, Jul 29, 2016
    #6
  7. desmotom

    desmotom Active Member

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    Also need new orings and washers for idle screws. Missing washers and orings looks swelled
     
    desmotom, Jul 29, 2016
    #7
  8. desmotom

    desmotom Active Member

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    image.jpeg Well... Brought her back to life today! Idles decent( had floats upside down ).
    Have a little more tuning to go.
     
    desmotom, Aug 1, 2016
    #8
  9. desmotom

    desmotom Active Member

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    image.jpeg Mocking up rear sets tonight..
     
    desmotom, Aug 2, 2016
    #9
    Toomanybikes likes this.
  10. Toomanybikes

    Toomanybikes Well-Known Member

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    Perfect way to do it with cardboard first
     
    Toomanybikes, Aug 3, 2016
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  11. Toomanybikes

    Toomanybikes Well-Known Member

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    Have seen upside down floats in Hitachi carbs before.. I think they are the only carb that floats fit in both ways. Terrible design
     
    Toomanybikes, Aug 3, 2016
    #11
  12. desmotom

    desmotom Active Member

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    they look like they should be upside down by the way they are shaped....
     
    desmotom, Aug 3, 2016
    #12
  13. desmotom

    desmotom Active Member

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    image.jpeg image.jpeg image.jpeg No more cartridge filters for this guy!
     
    desmotom, Aug 4, 2016
    #13
    k-moe likes this.
  14. dirtmax

    dirtmax Member

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    That's pretty cool!

    Is it working? What kind of filter is that?

    I need to release my 4 in 1 exhaust to swap filters.
     
    dirtmax, Aug 4, 2016
    #14
  15. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Chacal offers several filters with the adapter. I've had mine for over four years now and have been very pleased.
     
    k-moe, Aug 4, 2016
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    dirtmax likes this.
  16. desmotom

    desmotom Active Member

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    Made everything today, couldn't stand the mess with the cartridge filter. What 4-1 you have? My mac 4-1 lets me to remove the old filter.
     
    desmotom, Aug 4, 2016
    #16
  17. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Oh, you made that? No wonder it looks a bit different from the kit.
    Very well done.
     
    k-moe, Aug 4, 2016
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    desmotom likes this.
  18. Polock

    Polock Well-Known Member

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    is that blue from a Toyota FJ ?
    Prototrak lpm mill ?
     
    Polock, Aug 4, 2016
    #18
  19. dirtmax

    dirtmax Member

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    I guess you'll have to figure out if you need more (or less) then 2.5 liters of oil.

    This works with any kind of oil, ya? Like for example I'm using Rotella T.
     
    dirtmax, Aug 4, 2016
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  20. desmotom

    desmotom Active Member

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    Painted it before the FJ ever existed!
    HAAS Mill and lathe.
     
    desmotom, Aug 4, 2016
    #20
  21. dirtmax

    dirtmax Member

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    Honestly, I have no clue. My guess is it's mac. PO must have banged it somehow, now is off centre and filter cap starts pressing on one of the pipes as soon as I start unbolting it.

    ...now I'm thinking I could hit filter cap back as I'm unbolting.

    But I definitely like that design better.
     
    dirtmax, Aug 4, 2016
    #21
    desmotom likes this.
  22. desmotom

    desmotom Active Member

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    image.jpeg Started the disassembly this weekend.....
     
    desmotom, Aug 7, 2016
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  23. desmotom

    desmotom Active Member

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    finished up rear sets today, now have to mount and fab linkage. more pics to come! IMG_1387.JPG
     
    desmotom, Aug 9, 2016
    #23
    TheCrazyGnat likes this.
  24. MiGhost

    MiGhost Well-Known Member

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    You did know that fancy machine work requires multiple copies to be made for members, Correct?;)
    Nice looking metalwork. Wish I had the room to set my machines up again.

    ~Ghost
     
    MiGhost, Aug 11, 2016
    #24
    desmotom, TheCrazyGnat and k-moe like this.
  25. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I wish I had the money (and space) for more than my little Atlas lathe. A milling machine would be fun to make chips on.
     
    k-moe, Aug 11, 2016
    #25
    desmotom likes this.
  26. MiGhost

    MiGhost Well-Known Member

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    Had to let the shop, and big machines go in 03 due to the divorce, 08 pretty much wiped me out.
    Been slowly trying to rebuild a small shop since.

    ~Ghost
     
    MiGhost, Aug 11, 2016
    #26
    desmotom likes this.
  27. desmotom

    desmotom Active Member

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    Wish I had machines at home...I have a 1800 sqft shop and would love to have a mill and lathe!
     
    desmotom, Aug 11, 2016
    #27
  28. Polock

    Polock Well-Known Member

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    you sir are a knurling sob
    here's two quickie ideas for lunch time some day. brake rod and brake stay arm
    [​IMG]
     
    Polock, Aug 11, 2016
    #28
  29. desmotom

    desmotom Active Member

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    Nice! I like a challenge!!
     
    desmotom, Aug 11, 2016
    #29
  30. MiGhost

    MiGhost Well-Known Member

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    I am starting back up small using a couple chinese machines (Sieg X2, Big Dog 7X14). They are cheap and need a bit of work to dial them in properly. But space is limited at the moment. The bridgeport and 10" atlas were nice but way more than I needed for what I was doing with them.

    Got tired of shops quoting $250 set up fees for a $20 part. A simple We don't do small jobs would have worked just as well.

    ~Ghost
     
    MiGhost, Aug 12, 2016
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  31. desmotom

    desmotom Active Member

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    image.jpeg Security silicone? SIN #s engraved everywhere too.
     
    desmotom, Aug 12, 2016
    #31
  32. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Someone loved their things sooooo much.
     
    k-moe, Aug 12, 2016
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  33. desmotom

    desmotom Active Member

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    image.jpeg Hmmm....
     
    desmotom, Aug 13, 2016
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  34. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    That's better than just getting laughed at, which is pretty much the norm down here.........
     
    chacal, Aug 13, 2016
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  35. MiGhost

    MiGhost Well-Known Member

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    BTDT!
     
    MiGhost, Aug 13, 2016
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  36. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Usually $20 parts only cost $20 when you make a few hundred (or more) of them in each production run.
     
    k-moe, Aug 13, 2016
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  37. MattiThundrrr

    MattiThundrrr Not a guru

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    BTDT?
     
    MattiThundrrr, Aug 15, 2016
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  38. TheCrazyGnat

    TheCrazyGnat Well-Known Member

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    Been there, done that?
     
    TheCrazyGnat, Aug 15, 2016
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  39. MiGhost

    MiGhost Well-Known Member

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    And we have a winner!:D
     
    MiGhost, Aug 15, 2016
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  40. desmotom

    desmotom Active Member

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    finished clip ons, they are a little long right now, will trim once I am happy with length. Ordered new speedo and signal lights! Need to finish up rear set linkage then a complete tear down and start on the wiring. I want to do a minimal wiring job (cliché), I have a spare botched harness from a donor bike that I will use connectors from. Would like to put the larger rotors on from the 750 seca, might be a pain in the .... IMG_1420.JPG
     
    desmotom, Aug 16, 2016
    #40
  41. MiGhost

    MiGhost Well-Known Member

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    Larger rotors = relocated calipers. I am sure you can handle that.

    For Reference:
    http://www.metalgear.com.au/

    650 Seca Rotors: XJ650R
    Measurements (mm)
    Outside Diameter     267
    Inside Diameter 64
    Bolt Hole Circumference 80
    Bolt Hole Quantity 6
    Bolt Hole Size 8.5
    Thickness 5.0
    Minimum Thickness 4.5
    Offset 18.0

    750 Seca Rotors: XJ750R
    Measurements (mm)
    Outside Diameter     298
    Inside Diameter 64
    Bolt Hole Circumference 80
    Bolt Hole Quantity 6
    Bolt Hole Size 8.5
    Thickness 5.0
    Minimum Thickness 4.5
    Offset 18.0

    ~Ghost
     
    MiGhost, Aug 16, 2016
    #41
    desmotom likes this.
  42. desmotom

    desmotom Active Member

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    image.jpeg Got the clip ons on to see how they fit and look...pretty good I think. Don't hit the tank either with factory stops.
     
    desmotom, Aug 17, 2016
    #42
  43. desmotom

    desmotom Active Member

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    image.jpeg Think that will work. Will make a new one that will bolt from behind to attach to fork, and add some sexy to it! I'll probably 3D print the final model to make sure I like it before making chips.
     
    desmotom, Aug 17, 2016
    #43
  44. MiGhost

    MiGhost Well-Known Member

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    As long as the calipers run true with the disc! Looks good!
    ~Ghost
     
    MiGhost, Aug 17, 2016
    #44
  45. desmotom

    desmotom Active Member

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    image.jpeg Looks good with the blue filter and larger discs
     
    desmotom, Aug 20, 2016
    #45
    chacal and TheCrazyGnat like this.
  46. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    You could paint the mower blue, too............ :)
     
    chacal, Aug 20, 2016
    #46
    desmotom likes this.
  47. Stumplifter

    Stumplifter Well-Known Member

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    I see what looks like Craftsman on it. But at first glance it looks a lot like a Toro Wheel Horse with a Kohler C20 in it?

    Just got done replacing the stator on mine, very proud to say I was able to remove everything withOUT pulling the horizontal motor!

    Apologies for the hi-jack and braggadocio. :confused:
     
    Stumplifter, Aug 21, 2016
    #47
  48. desmotom

    desmotom Active Member

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    It's a craftsman with a kohler!

    Started on the control linkage, and seat cowl. Getting sidelined now, my ranger was jealous and decided to drop a valve :(. Found another engine, just have to freshen it up. Never a dull moment
     
    desmotom, Aug 21, 2016
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  49. desmotom

    desmotom Active Member

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    image.jpeg Finally got some time to work on the bike! Work and home has been so busy lately. Got the shift linkage mocked up, need to get shoulder bolts for the pivot points and prob gonna replace the threaded rod with a. Aluminum rod in the future. The brake side I have fab a bracket, but I am using the factory shaft and linkage.
     
    desmotom, Sep 10, 2016
    #49
  50. desmotom

    desmotom Active Member

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    haven't updated my project in a while, still working on it. starting the wiring soon (winter project). Anodizing all the parts I made also, and also have a few more parts to make. Ordered a new seat which should be here any day and a keyless ignition kit. Relocating project to my basement for the winter, gets too cold up here, and my shop takes a while to heat up. ranger is almost done though;)
     
    desmotom, Nov 24, 2016
    #50

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