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Advice please

Discussion in 'XJ Technical Chat' started by Ken Davies, Jul 22, 2022.

  1. Ken Davies

    Ken Davies New Member

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    Hi All
    Welsh boy from over the pond and new to this forum, bought myself XJ650 Maxim 1982 import non runner to fettle in my twilight years, after fifty years with assortment of bikes, mostly Yamaha, rigged battery up to test lighting etc, i'm stuffed on this question;
    • Has the bike need to be running for headlight to work?
    • Obvious the light control switch is on the left of handlebar, is this just lights on/hi beam only?
    • Turned ignition on, indicators/horn & tail light work but nothing else, is this right for this model?
    Previous; owned XJ750 Seca UK spec and two FJ1200 all had light switch on right (throttle side).

    This model is all new to me, any advice and help most appreciated.

    The non runner part is two pistons stuck in cylinder 3 & 4 rusted rings to barrel due to years in storage, tried all the tips on this forum soaking but no luck.

    Kind regards
    Ken
     
  2. OPCRacer212

    OPCRacer212 New Member

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    Yes, the engine needs to be running for headlight to come on.
     
  3. JCH

    JCH Active Member

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    Easiest and cheapest in my opinion is find a used motor Ken.
    Can you post some photos ?
     
  4. Ken Davies

    Ken Davies New Member

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    Appreciate reply, thank you.
     
  5. k-moe

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

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    North American motorcycles are required to have the headlight at all times when the engine is running, so there's no switch to turn it off with.

    The pistons and cylinders are the same as on the standard xj650, so you should be able to find a good set if you need to. Oversize pistons and rings are not easy to find, but of course they can be made and you're in the right country for having that done relatively inexpensively.

    Are you sure that it's stuck pistons and not a problem in the transmission or with the HY-VO chain that's keeping the crankshaft from turning? I only ask because if that's the case a different engine would absolutely be easier and cheaper.
     
  6. Minimutly

    Minimutly Well-Known Member

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    Lol at the "being in the right country for having cheap pistons made".
    On my seca (uk spec I think) the hi/low beam is on the left, the off on park is on the right. Same for the JDM import 650 maxim. The maxim doesn't have the Yamaha self cancelling indicators.
     
  7. k-moe

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

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    I did say relatively cheap. There are a ton more small machine shops over there that will work on that sort of project, at least that's what I've been lead to believe.
     
  8. Minimutly

    Minimutly Well-Known Member

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    I wish, but you may be right.
     
  9. k-moe

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

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    I also may be crazy ;)
     
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  10. Ken Davies

    Ken Davies New Member

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    It's looking as i have someone to buy it as it is. Now have my eye on 750 Seca, been here before and know all about them.
     
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  11. Ken Davies

    Ken Davies New Member

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    You couldn't write a book on my bad luck :( chap buying it got taken to hospital on morning of sale.
     
  12. faffi

    faffi Active Member

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    Well, if you look at the bright side, you did not have to be admitted to hospital on the morning of sale.
     
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  13. Ken Davies

    Ken Davies New Member

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  14. Ken Davies

    Ken Davies New Member

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    Staying with topic, might as well keep it and put on my big boy pants and get them spanners working, but first, i need to aske a few more questions.
    • On the removal of rocker cover which by the way is immaculate inside and everything as it should be, no sign it was anything other than rusted piston rings that is the cause of locked engine. Do i remove the camshaft caps and slide cams out as impossible to get to bolts on chain sprocket.
     
  15. Ken Davies

    Ken Davies New Member

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  16. Ken Davies

    Ken Davies New Member

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    This is the replacement part i have.
    [​IMG]
     
  17. Franz

    Franz Well-Known Member

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    Don't remove the caps. The sprocket bolts can be removed. But you have to remove the two carriers the cam cover bolts go into on that side of the engine. The camshaft caps don't have bolt holes in the centre of them.
     
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  18. Franz

    Franz Well-Known Member

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    Like this. You can use a spanner to stop the cam rotating when removing the sprocket bolts.



    16598064825657131116560300017204.jpg 16598062856731844546919145072792.jpg
     
    Last edited: Aug 6, 2022
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  19. Franz

    Franz Well-Known Member

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    Have you got a Haynes manual for your bike?
     
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  20. Franz

    Franz Well-Known Member

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    Seen the photos of the damage so you need a new head and cams too. Can you get the head off the engine the barrels and pistons came from?
     

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