Biggo,s Covid XJ900f Rebuild

I have a 1986 XJ900F that I have owned for over 30 years so when I see a non-runner for sale for $400 I thought it must be good as a spares bike. We went into COVID lockdown here in New Zealand so I though I would try and get it running. Some oil down the bores got it turning over a strip of the carbs and the exhaust borrowed from my other XJ and she ran. Should I strip or should I re build that was the question ?

 

My thoughts go to what is it worth to you. I am more of a rehab and make it a nice runner guy. Rather than a restore and make it a museum like piece. I appreciate the time, effort, cost and effect of the piece by piece restoration but don't have the dedication to the project. There are bikes out there that are worth more when done due to their own history but I have not had one yet. The cost of going from a nice safe daily rider to the perfect show piece goes up fast.
What ever you do with it, primarily..... Have Fun!
John

 

I’m about to do the same thing 84 750 it does come down to what’s the purpose I just like taking things apart and making them better

 

If your other XJ is your everyday runner you can take your time over the rebuild depending on how much you intend to spend on it. What exhaust system do you have on the bike?

 

My other XJ is my nice day ride that I am very attached too. My son wants it when I am past riding and I am sure it will mean the same to him. The exhaust on the other bike is totally shot however I have a 4 into 1 system that I will swap with a reasonable aftermarket exhaust with a friend who is doing a cafe racer XJ

 

Hi John .

The decision I made was to do a rebuild on a budget but to get a good reliable everyday runner .

Phil

 

So I have established the bike has good compressions on all cylinders but Carbs still need some TLC . Time to strip the old girl down and see what else we need.

• Frame is surprisingly good condition was able to get sandblasted before lockdown but not powdercoated or painted so decided to go for brush pained hammerite finish.
• Front forks leaking but I have a spare set in the shed so work out which ones are best and refurb as required.
• Steering bearings knackered so got some bearings with built in seals
• 4 times carb overhaul kits and brass fuel tee piece ordered.
• New swing arm bearings and clean and paint as required
• Wiring loom cleaned and all connectors treated with white vinegar / Baking soda and finally ACF50 all connection like new now
• New fusebox fitted
• Dash housing repaired from previous drop
• All brake calipers and master cylinders stripped and clean a couple of new seals required
• 2nd hand exhaust welded up as required and painted with VHT paint.
• Engine just cleaned and serviced before re fitting

 

Glad to hear the refurbish is going well. Looks like it is going to be a real nice job, something to be proud of. Watch your budget creep. I have a Midnight Maxim 750 I picked up VERY inexpensively (initially anyway) and had it going nicely and then decided to fix this, then that and now have got my own Project Creep going on! But is not going to be as extensive as yours.
John

 

Good degrease and clean off of engine . Some of the exhaust studs were quiet rusty when dismantled so run a die down then an I dont want to shear one of those off.
As I am doing this on my own in lockdown I think I will fit the frame to the engine while its on its side. Airbox fitted first as I know there is no wat to get it in after motor installed. I want to keep this stock no pod filters etc . Also checked generator brushes which were like new and cleaned and painted starter motor and generally cleaned up all electrical connections etc.

 

Wow seeing that gets a little intimidating on me doing mine.......I’m still on fence about picking up this 84 750s motor wise.....any suggestions when I go have a look ?

 

These bikes are not the most difficult to work . I would check engine out if it runs that may be the difference between an engine re build or not which can add plenty of $$.
My Plan is to get this running a good functional bike not a show bike but safe and practical > I intend to leave it standard except maybe some minor Farkles . Good luck with your bike

Phil

 

Hey Phil so just got back from a 4h round trip to pick it up I couldn’t resist it....but severe rust in tank should I just assume and go ahead with motor tare down or just the carbs?

 

Hey Marchy. Personally I would try and get it running first just so you can make a reasonable assessment before stripping . unless you are going for full rebuild anyway.
My other XJ rusted ot the back of the tank many years ago, I was able to solder up pinholes and used POR15 tank liner kit that was about 20 years ago and its still holding up OK

 

Hey Phil

got ahold of the bike yesterday night and
ya think I am going rebuild just cuz the neglect and I am planning on putting money into this one as a show piece......could you direct me to any good threads

 

So engine in and secure next I think is rear swingarm.
Replaced swingarm bearings getting outer race out of swingarm proved challenging.
I had a bearing puller I used on some head bearings that looked like it may do the job . Needed a bit of modification and then how do I knock it out of a blind hole
Solution was to drill a hole to allow a punch through from the other side .
New bearings in so clean off swingarm and paint then fitted to bike

 

So that swing arm is painted right?

 

Correct I just used spray can of wheel silver. Happy with result

 

Next to put on new Steering bearings trfot front forks and wheels on so I can stand bike up . All going to plan so thats good

 

It is great seeing these old Yamaha's put back on the road.

 

Got her all running been for some good long runs . Clutch is breaking away at high speed in top gear thought it may have been because it was frozen when I first got it running but know so new Clutch to be done next

 

That is beautiful! NICE JOB!!!

 

New Clutch fitted sorted out perfectly with new cable as well.
Have been using as my main bike really enjoying riding her.
I made up a mudflap try and keep front of engine clean but this ended up after a couple of thousand KM,s cracking the mudguard . Had a spare one to use while I repaired white one but now decided not to worry about keeping engine clean ! The motto for this bike is definitely " Ridden not Hidden "
I have now done about 5000 kms since rebuild and she is running sweet

 

That is a sweet setup. Well done sir! I do like the fairing stays that sweep around the side of the tank. I can see where in a drop they would bugger the tank but the answer to that is don't drop it. Very nice. I like.
John

 

Nice machine what make are the engine bars?

 

Fennick I think they are called. I got them in the UK late 1980s
Very well made and good protection

 

Sorry Renntech is the make

 

Cheers l will try and get a set.

 

Done a few more thousand kms. and worn out my tyres. Fitted set of BT46. Very pleased with them so off on a motorcycle rally later in the week to South Island of New Zealand. Should do 4 to 5000 kms.

https://www.tt2000.org/index.html

 

If you can do 5k in a week you're tougher than I am!
For those not familiar with nz roads, we don't have many straight bits. The roads are narrow & windy with patches of gravel here & there to keep you awake. So after 6-700 kms you feel like you've been put through the wringer, but if you know where to ride the traffic's not bad and they are great m/c roads. I went for a high speed run around the back roads of Rotorua on Sunday, was worn out after only 200km. Anyway good luck with the rally.

 

Hi Brent.

Always found the XJ comfortable on long rides . My plan for Rally at the end of the week is about 500 kms on Friday then 1100 kms on Saturday finally about 400 Sunday Morning . I will then do another 2 - 3000 plus getting to and back from Oamaru for TT2000 Rally . I will be getting ferry to south island in the morning .

I will have a spotwalla tracker on tomorrow if anyone is interested

https://spotwalla.com/tripViewer.ph...9hFi35_xPrARXFN0u_H798mNwf6MzgHK0LsRZ7GuZk0Tg

 

I am sold!
How does a 60 yo frozen Canadian ready for retirement immigrate to this enchanted land?

 

I kept an eye on your tracker, what an epic trip!

 

3000 kms so far. Epic roads lots of curves gravel roads too. XJ has been flawless.
500kms today then home the following day. Bike needs to a good clean.

 

A question for when you are finished - what was the best road? Queenstown to Glenorchy?

 

Hard to choose.
Great ride through haast pass this morning and I love Arthur's pass but Glenorcy rd always good.

The south island is all motorcycling heaven

 

Bach home now after 4600 Km,s of great riding . A few pics from the Rally

 

Excellent, New Zealand on my bucket list. What's with all the ladies underwear on that fence?

 

Started of as a gimmick but raises money for Brest Cancer . Quite a tourist attraction but no foreign tourists allowed in while we are COVID free here in NZ

https://www.stuff.co.nz/travel/dest...-famous-in-new-zealand-the-cardrona-bra-fence

 

The old 900 still looks good compared with the newer stuff. Well done mate.

 

I like bikes where the engine is not covered with fairings, they look good and there is ease of access for maintenance. .

 

A local guy made me a nice sheepskin cover for the XJ Very comfy had one on my FJ1200 a few years ago .

 

Done just over 12000kms now since rebuild. Service time including valve clearances using the wire under the valve method , need to order some shims tomorrow . Bike going great

 

Planning to do an Iron Butt SS1600 ride on the old XJ
Ride will be Winter Solstice ride on 21st June ( Winter in southern hemisphere )
I will only go if weather reasonable I dont see it as fun to be riding 1000 miles in pouring rain !
Map of planned route below

https://goo.gl/maps/cii852KusS3WqqRq5

 

Been in lockdown again here in NZ.
Few jobs to do on the old girl .
Slight fuel leak from No3 carb appeared to be float chamber gasket so off with the carbs and new gasket fitted . What a bastard getting the Inlet rubber that have gone hard over the years back on . Ended up boiling them in water before inserting through the air box onto carbs.
I followed the bike when I let my son have a ride a few weeks ago after long downhill sections using the engine as a break getting a puff of smoke from left exhaust . It is using about 1 litre of oil every 1200 km,s . I suspect the valve stem seals have gone hard so another job for the list but for now I can live with a bit of oil consumption.
Fitted some extra spotlights for night riding as the original headlight leaves a bit to be desired .
I am still loving this bike and look forward to plenty of happy KM,s this year

 

Well I haven't been giving my XJ the love . Decided to take it for it Warrant of Fitness inspection last week as havnt used it for a few months and it had expired. Left home early going well then Rev counter dropped to zero and bike died . Coasted to the hard shoulder lucky not much traffic around.
Checked over electrics everything working but no ignition starter turning over and all lights working properly. Fiddled around with all wiring blocks fuses etc but no good.

Phoned my Son in Law and asked him to rescue me with his trailer. Loaded on bike and took it home . Got bike off trailer and though I will just give it another go and off course it started first time !!!!

I cant get the fault to re occur but suspect it could be TCI unit so lucky I have a spare I will pop it under the seat so I can quickly swap if require in future.

Don't you just love intermittent electrical gremlins !!!!

 

Tried another TCI unit and seems to run OK . I am also thinking about new ignition coils as they are nearly 40 years old.
Going to put bike away for the winter so will get her back out around Christmas

 

Time to get out my other XJ900F.
This one is a 1986 model I brought with me from UK. A friend of mine bought it brand new and I took it off him when about 4 years old so owned it about 33 year's.
The frame has rusted out so time for some major work.

 

After a few Months of not doing much I spent the weekend re assembling my XJ900 . Just clean up and refit mainly.
I did find some bad burnt wiring connectors from Alternator so fitted ne terminals .
Hope to give the carbs a clean in the ultrasonic cleaner next week then be ready to fire her up after 4 years