Xj 650 turbo 1982

Hi

I have a xj 650 turbo of my Friend to restore.

I dont know very well this bike.

Do you have tips to restore this bike ?
What i need to see ?
What is problems on this bike ?
What Can i need to look about the turbo (lubrification?)

For the story, the bike have 68 000KM. She had a rebuilt engine (except clutch). My friend had a clutch problem and send the bike in another shop to repair the clutch. But low time after, a rod get out the engine.

An expert look the bike and said it was a problem of oil because parts of new clutch block the strainer (
disk thickness problem).

The expert said the shop need to rebuilt the bike to have a funcionnal bike. But the shop put a XJ 650 (not turbo) engine on the bike with manifomd and turbo on the wrong engine).

The bike never run well and today, the bike have a 4KO engine.

Tne project of restoration is put a used engine 11T with
reconditionedreconditionned turbo

Thanks a lot

I'am french, my english is not very well. Sorry

 

Welcome to the forum @Rammstein86380 always fun to focus talk on the Turbos.
Of the OEM Turbo bikes the Yamaha is the most basic and easiest to work on.
Much of the running gear is standard XJ stuff, however you really need to study the supplementary manual for the Turbo.
If you send me a private message with your email I can send you a pdf copy, Canadian actually so it has French and English text.
After you study the manual you need to go through the bike and make sure all the auxiliary stuff for the turbo is still there.

The fact it has a standard 650 engine installed raises questions;
There is oil feed to the turbocharger coming from the crankshaft oil galley.
Did they drill and tap the cases to accept the oil check valve?
The oil return from the turbocharger enters the oil pan and a scavenge pump is piggy-backed onto the main oil pump.
This combo turbo oil pump (and oil pan) could be installed into the standard motor but the chain and sprockets are different.
To install the turbo oil pump and the proper chain and sprockets requires splitting the cases, did they do this?

The turbo has special short duration camshafts, did they install these?
The standard XJ motor has higher compression, this will probably be ok if the knock sensor and ignition advance is functioning.
Is the knock sensor installed? It is at the front of the cylinder block between cylinders 2/3.
YICS motors have the boss for this and can be drilled and tapped to accept the knock sensor.
Non-YICS motors do not have the boss, so it would need to be weld built-up then machined, drilled and tapped.

Post lots of pictures here and we can help with your assessment.

 

I will make more photos but i think they put the oil case of XJ turbo on normal engine to have the turbo oil hose (i see one metalic hose under the oil case to the turbo)

But i think the camshafts are normal camshafts and the normal oil pump

For the moment, i must restart the engine and took compression. I think i will sold this engine to buy a turbo engine

Carburetor are very dirty

 

I want to post photos but i have an error message

 

you need 5 posts before it will allow you to send pics

 

Ok thanks 5 post on my topic or 5 post on other topics ?

 

The posts can be anything.

 

Ok thanks

 

interesting that is a standard motor installed or at least the head.
In one pic you can see mechanical tach drive not hooked up to anything.

 

that makes it a non-YICS motor.
If the knock sensor is not installed then it won't run right.

 

a peculiar fact with the XJ650's yics and non-yics
the Turbo is an 82 650YICS but it's valve cover interchanges with the 650 non-YICS
the 650 YICS motors do not interchange so those turbo air scoops are still there in one pic

 

Thanks simmy. I think i will put a Real turbo motor.

Can you send me the manual please ?

 

ok working on it

 

Thanks a lot simmy

 

Hi. Where Can i find the reference on mikuni carburetor assy to be sure it's a Turbo carburetor ?

Thanks

 

https://www.partzilla.com/catalog/yamaha/motorcycle/1982/xj650lj/carburetor

 

The simplest way to verify the Turbo carbs is to pull off the float bowl and see whether there is a FLAT GASKET or an O-RING that seals the bowl to the carb body......very few carb sets used this method (although there are a few others). Also, under the choke plunger valve brass SCREW-IN SEAT there will be an o-rings.........I don't think any other non-Turbo carbs featured an o-ring in that position.

 

Hi

Do you have a photo of knock sensor please ?

 

here are schematics below.
it's a small microphone device that screws into the cylinder block, at the front between 2&3
Look for 2 wires coming from there which plug into the wiring harness.

 

I took this pic to show a 900 block can be drilled to accept the knock sensor shown.
The non-YICS motors do not have this boss so I don't know what they did on your motor

 

Hi

Good news, i find a Turbo motor to change.
And the turbo is in workshop to be repair.

I will post photos.

I search 3 parts :
The metal bracket for fuel pump
The Switch lead on the master cylinder
The center cap of handlebar cover

If you have that.

Thanks

 

Hi

I have one problem with my intake rubber on the Turbo.

I have this type of cylinder head with two intake rubber in one side (right) and two intake rubber in another side (left).

https://www.ebay.fr/itm/15539976398...mQGyYcDQyK&var=&widget_ver=artemis&media=COPY

Can i put 4 intake rubber of xj 650 non turbo without problem of orientation ?

I think xj non turbo have 4 intake rubber in the same way

Thanks

 

There are 2 different bolt patterns for XJ650's I think you're already aware if I understand your question.
if the new replacement turbo motor has the intake drillings like the 2nd pic below this is correct.
If you're going to use non-Turbo intake rubbers you have to make sure you specify for the YICS XJ650, otherwise you can end up receiving the ones to fit the 1st pic.
I suspect you can make them fit. If you can't find Turbo replacements its probably the best option.
Note that the Turbo intake rubbers have an O-ring for extra sealing under boost pressure.
For your case I would smear both sides of the gasket with silicone to help hold the boost.

 

Thanks simmy.

I have the second cylinder head.

I found intake rubber for xj 750 who have the cylinder head with 2 intake rubber right and 2 intake rubber left. I will order that and put silicone.

Thanks