82 Maxim XJ1100 Dark Knight Build

Hey guys,

So I picked up my project bike as that, a project. The bike was in perfect working order and has the bones I want, but not the style. All my friends bugged me to just go riding with them but I had other ideas.

After watching these forums and doing some research the XJ1100 caught my eye, its unique and somewhat rare. I know alot of guys restore it back to factory but I wanted a full custom look without the custom pricetag. I also wanted to make the build simple enough I could do the majority of the work myself bit by bit without any rush.

As things turned out I got the bike for $1000 in beautiful shape as seen below. I thought it would just be a case of a some mild tuning and a paint job. Then my engineering and design / love of painting everything took over.

As my parents can attest I will paint anything I can to make it just the way I want it.

First I started with stripping down the fenders and gas tank, then came removing the rear end to make room for a bobber fender. I got a 6" fender which fits perfectly around the stock tire and I will fabricate a couple mounts for it. Also instead of tail lights on the fender I have a nice LED under seat brake light/ signal combination I will mount.

I also got some LED bolts for the license plate and a side axel mount plate holder (I will take a picture of this later)

Clearly the exhaust had to come off as well. I have picked up a yoshimura GSXR 1000 dual pipe exhuast that I will get painted gloss black to match the bike and utilize the stock headers and midpipes.

I will be attempting to mount the pipes lower, similar to the stock cones. There are bolt holes for the rear sets which I will not be putting back on the bike so I will create a hanger from them.

Once I settled on this I went to work stripping the bike making sure to label all connections and parts that I would be reusing.


I will try to post on my continued tear down and rebuild as I can. I currently have all the wiring off the bike and its stripped down the a rolling frame with tires. I'll snap some more pictures and share some more I have including the new headlight shortly.

 

Gloves?
Com'on, get your hands dirty. Its good for ya'

 

I love a stock bike but I also love a well done custom. Unfortunately many threads start like this and end up with the poster going dark. Good luck with your build and I'm excited to see what you come up with!

 

What is going to happen to the parts you are not going to reuse? I'm interested in the exhaust

 

The gloves came about because i usually end up cooking dinner after the garage and that grease is not quick to come off, also my fiancee kindly suggested them one night haha.
As for parts I still have the split handle bars, signals, rear fender, rear lights and other miscellaneous.

As for exhaust the only section I'm not reusing is the cones at the rear, I still need/ want to utilize the H-pipe and headers

 

Current state of the bike now. From here I will begin to update. Still working on the back end and proper fender supports.

 

This looks to be a cool project.
I wanted to buy a 1100 to build, but could find one in my price range.. Ended up with a 750.
But I'm tuned in to see how this turns out...

 

If mlew does not pick these up. Let me know I am interested in getting them.

~Ghost

 

I'm interested in this too... keep us posted.

 

I have them sitting in my garage

 

So not a bike progress as the bike is still the same. On the weekend I focused on getting the garage in order so I can work happily all winter in there. New shelving and a homemade hockey locker were in order.

Now that the garage is nearly out of the way I need to line up a welder and design my new rear fender supports.
The next post will be progress!!

 

Can you send me some pics and a price?

~Ghost

 

At least you have a garage to work in threw the winter!
I have a 10x10 shed. But I'll make it work for me.. lol

 

Mine is only 8x8 and works great for the lawn mower!

~Ghost

 

Lol..
The lawnmower can sit in the snow.
I have more important things to keep in there.
Mines insulated, and is my workshop.. It's lame, but better than being outside when it's 20 below!

 

two computer screens a stereo a flat screen tv, hockey season is starting, you'll never get that bike done

 

You know it bud!! lol

 

Give 'er, eh?

 

I'll take some pics tonight !

 

Here is the condition of the cones, some minor rust but solid.

 

And I started playing hockey so yes it's going to be a battle to finish this thing.

 

So I've been pouring over the forums and threads and stumbled on the spin on oil filter conversion. I'd like to do this on my bike as I plan to drain it and need to replace a few seals anyway. Where can I order the spin on oil filter conversion that I've seen on here ??

 

Xj4ever - the link is at the top right corner of the page.

 

So I finally have some progress and a welder coming in the morning to build my supports !! So I've taped up where I want the fender with spacers underneath it for clearance.

The dark line is a potential cut spot but I'm not too sure of the back end cut just yet.

 

So sadly the welder didn't read my messages entirely. Regardless I have some progress !!

The seat plate has been welded. I put it at a the back of the frame and I will have to fabricate a front bracket for it later.

The cut pipe ends have been covered and smoothed around.

Seeing all this done I might take a welding course in the spring for future projects.

 

Heavy duty plate!

 

The welder said 1/4" plate so I got 1/4" plate. Second welder came tonight and I should have my fender supports done by the weekend ! Pumped to finally see some serious progress and and then its off to paint followed by rewiring.

 

So my supports turned into a more simple necessity than anything. Plus I didn't want to spend a fortune getting them built so here they are


I realized I shouldn't be too worried about them as my exhaust will more or less cover them. I think I'll be building exhaust hangers either from the shock mounts or where the rear sets used to be.

Held the exhaust up to get an idea but I'm not sure on the angle I want them to be at but not flat like they were stock.

Everything will be going gloss black with nothing shiny or chrome left on the bike. All black with a single blue racing stripe down the middle of everything.

 

I can't wait to hear the 1100 with that fart cannon you've got! Should sound pretty evil.

 

Yeah I've had a buddies give me grief over it but I have always loved riding my sport bike when you reach that drone on the throttle. I needed a cruiser/bobber to slow me down a bit. I think they'll make the final design but I'm not fully sold yet.

 

Just bought a xj1100 here in Calgary... would love to check out your build sometime

 

Plus to you for your creative mind but sad to see a complete machine chopped up.

I can see where your going with the build and anxious to see more. And, hopefully a video at the end to see her screaming down the road.

Here's a guy that did a 4 to 1 with an Akrapovic. Sounds good, your 1100 is near twice as big so it should sound twice as nice!

 

It'd be great to meet a fellow builder locally. Shoot me an email with what you picked up ! Drevillp@hotmail.com

 

Thanks for that link ! That does sound awesome ! The bike needed some talc and I needed a new project, stock is not for me. I've spent plenty of time in Texas, if I get down again I'll need to see your machine.

 

Hey asg,
Whereabouts in the city are you ??

 

Well I've finally managed to find some time to live in the garage while the fiancée is at work.

My fenders have been cut and should see paint this week. I'll post pics of them later.

Over the holidays I've got my wheels painted, rotor centres painted, bars ordered, lower forks painted and the custom rear fender mounts all cleaned up. Painting was the easy part, cleaning off the 30ish years of grime was time consuming.

Oh and I reassembled my carbs which will likely need to be pulled for new jest once the build is complete for a tune.

Let me know your thoughts

 

Did you rebuild the forks before you painted the lowers?

 

The bike was fully functioning before I got into it. As for the forks I didn't remove them to paint them so I saw no reason to rebuild.

However once complete the shop I go to is going to give it a full mechanical for me.

 

So I've got the wheels back on post paint and I'm loving the way it's coming together. I discovered I have to get new pads for the rear for sure.
One complete a full mechanical in the shop is in order.

 

Stay away from shops. Nobody will do the work as thoroughly as you will.
30 year old fork oil and seals that are likely on their last leg.
Do all of the things now, so you aren't chasing your tail later.

 

What are you using for paint?

 

For paint I am using a normal gray primer from canadian tire. For the black its a tremclad high gloss black which looks good but not shiny enough, then I'm using a full coat of high gloss clear coat over that for that extra shiny wet look. All the paints are the off the shelf stuff from Canadian tire. My brother in law is painting the fenders for me professionally. The bike is a hobby more than anything so it won;e be showroom but it should look pretty sharp when done.

 

It doesn't sound too much loud to me, Actually, it sounds more quiet than my Kerker on my Seca900. I'd be tempted to fit one on it. Did anyone try it already?

 

Hey guys, just a quick update. I put the bike in for some minor seal repairs and some powder coating. I'll be getting the rest of the paint done for the frame and engine in my garage and then it's time to fab up the new speedo sensor mount and exhaust hangers.

 

So I missed some big gaps in progress in the garage I figured I should post. So I reassembled my carbs and due to all the warnings everyone shared I am going to run the stock airbox this upcoming season and then maybe next season get the jets done if I swap the filters.
The forks look beautiful and dripping wet in black along with the wheels, rear final drive and all the powder coating. Once I get the engine all cleaned up I am going to coat it in high heat black and trace out yamaha on the covers in white to make it all pop. The fairings are getting there first coat of primer and then silver early next week and then the blue will go on. Looking at my rear supports if I ever do this again I have a much cleaner idea as to how to build them and where to weld the supports.
I'm also trying to fab up my nice single centre mount gauge and bracket. The speedo is digital and not mechanical so I have to make a mount for the sensor and I'm thinking about chopping the mechanical speedo cable but have to keep it in the wheel assembly as the built in spacer. I'm actually kind of torn now about the single gage I have now or this other one that keeps popping up.


The exhaust I will be working on shortly wrapping it in black wrap from the headers to the can. the GXS-R 1000 exhaust I bought fits perfectly onto the end of the stock pipes where the original cone exhaust was which saves some fab work.

To throw a wrench in it all another XJ1100 came up for sale with a bent fork after falling off a truck locally for $500 and I am super tempted to grab it and have another one either for parts or to go a more stock route. Thoughts ???

 

If some is good, then more is better!

 

Speedo and tach positions need swapped on that first set.

 

you need something like this for that speedo

 

You're right, that's exactly what I need. Where do you get one of those??

 

i made that a long time ago