XJ650RJ Project

What the ungodly . . .

 

I did them in May 2022 and it's still going strong. I only use non-oxy gas in it (not sure if ethanol will do anything to the liner, I just want to avoid crud buildup in the carbs).

 

Great l am going to try it. I have three tanks for my 900f but one is very rusty. I have seen people on YouTube using POR15 but not using the recommended tank clean products sold by the same company.

 

Their metal prep seems a lot like a generic phosphoric acid metal prep - will remove rust, etch, and phosphorize the surface.

I would (at the very least) clean the bulk of the rust out using electrolysis or an acid method, and then use phosphoric acid or their metal prep.

 

Yes it's all about the preparation getting the sealer to bond property. I will get the acid for it.

 

Was a grease gun used to bleed the brakes?

 

Sprayed lots of parts today

 

Looks very nice Dan, but don't you think you will wear the paint off the levers rather quickly?

 

That's a good question. They came painted from the factory. I hope my paint job lasts at least as well as the OEM paint job.

The OEM didn't do a very good job of prepping the substrate originally, that's for sure. The aluminum was still pretty shiny when I stripped the paint.

The original paint must have been some sort of lacquer crap. It peeled off pretty easy after a couple minutes of soaking in lacquer thinner. Hopefully modern urethanes will perform better.

 

Got some paint from @chacal and got the final drive bits painted. Also got the fork lowers cleared.

 

Forks done!

 

Anybody know how to get these gauge faces off without destroying them? I was hoping to get inside and clean/lube the mechanisms, but it seems like it may not be worth the risk. @hogfiddles ??

 

Dan, I haven't attempted it on these specific gages, but the construction of most is crimped together at assembly like a can of beans. Very careful deconstruction by a tiny screwdriver or prying device, lifting the crimp little by little. I've only done it on gages where they are junk if not opened and repaired, and it was ugly.

But I've seen videos of it being done in a near restoration manner by folks with more patience than me, so it's possible.

 

that’s what I’m afraid of - might do more harm than good. Maybe I’ll just try to get a little lubricant in where I can.

 

Dan, i did a write- up on just how to get into the 700 maxim/X/virago gauges and this would take the same approach.

Here is a link, for your reading pleasure—-

http://www.xj4ever.com/repairing%20your%20700%20gauges.pdf

 

Got the fuse box crossed off the list

 

Did you get the gauges done?

 

I decided not to tear into the gauges to try to clean and lube them. The whole “if it ain’t broke don’t fix it” thing. I will get new speedo and tach cables and hope for the best.

 

Question on your fuse box, have you put the seat back on yet? I found that the fuse box I used was too tall. I did 2 things. I 3D printed a lower profile cover, then I mounted the fuse box further back on the top of the air filter cover. Mine is actually at an angle as my wires would not reach that far.

 

@Melnic - I did test fit the seat to check to see if I needed to modify anything - didn't see any problems. I don't think it is nearly as tight under the XJ650RJ seat as it is under the Maxim seat. I *do* need to replace the fuse box on my Maxim one of these days - I'm sure that will be more interesting.