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'82 XJ650 Turbo help

Discussion in 'XJ Technical Chat' started by Thanos Stavrou, Jun 20, 2024.

  1. Thanos Stavrou

    Thanos Stavrou New Member

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    Hello there, new to the forum. Started fixing my dad's '82 xj650 turbo. I need some info:
    1) Is this carb rebuild kit suitable for my bike?
    2) Does anyone have info on how to completely tune the carbs?
    3) Has anyone found a different turbo that fits the bike?

    (The bike doesn't have a turbo because it broke a long time ago. Also it has been sitting from 2005)
     

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  2. Simmy

    Simmy Well-Known Member

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    many of the parts there will not fit the Turbo.
    Typically the jets will clean up just fine. The rubber parts all need replacement - 42 years old now.
    I suggest a complete tear down of your existing carbs before buying anything.
    I suggest sourcing a replacement turbo unit before spending anything on this bike.
    Our vendor here on this site has everything you might need. XJ4ever.com

    yes, search this site "church of clean" and read this even before you even tear down your set.
    I'm not aware of one. It's too bad you don't have the original, it might have been rebuildable.
    eBay is likely your best place to search. XJ4ever.com is another
    In my opinion, without sourcing a rebuildable turbo unit you have a parts bike.
     
  3. Thanos Stavrou

    Thanos Stavrou New Member

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    Wow thanks a lot. I didn't know if this site was dead or not.I disagree a bit on the parts bike. It's like a regular xj650 I want to buy a turbo but alsoI want to make sure the bike works before buying a 300$ turbo from ebay.
     
  4. Simmy

    Simmy Well-Known Member

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    Yea parts bike was harsh
    How long has this bike been sitting?
    Was it ridden without a turbo?
    If all the turbo auxiliaries are intact then you have an awesome obligation to get it running that way. Dad’s bike to.
    The Yamaha turbo is easiest of the OEM turbo to restore. If you decide to proceed there is nothing stopping it from running
    Post some pics
     
  5. Thanos Stavrou

    Thanos Stavrou New Member

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    The bike had been sitting from 2005. Today I managed to pour some gas in the cylinders and it ran for 4 seconds.
    It had been running without a turbo for 4 years.
    I'm going to clean the carbs and I think it will fire up.
    Also do you know a good replacement fuel pump? The Yamaha one is dead
    Here are some pics from the carbs. I'll post more when I'll be back in town
     

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    Last edited: Jun 21, 2024
  6. Simmy

    Simmy Well-Known Member

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    Running without the turbo poses a few questions.
    What does the modification to the exhaust look like?
    Are there still oil lines to/from the turbo?

    Fuel pump, you can try soaking it in something which might free it up.
    Put it on the bench and hook 12V directly to it. Reverse the polarity to see if you can get it to rock back and forth.
    Failing that, I recommend a Walbro GSL395 as it takes just 2A of current.
    Most auto fuel pumps take 6A+ and the XJ electrical system does not have much in reserve.

    If you're not running a turbo then a fuel pump is not even needed.
    All it's doing now is pushing open the fuel check valve.
    You could bypass the fuel pump and check valve completely, go directly from the petcock to the carb inlet.
    The fuel pressure regulator should stop gas traveling back through the fuel return line to the petcock, if not it could be plugged, very simple.
     
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  7. Thanos Stavrou

    Thanos Stavrou New Member

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    I haven't really looked at the modification, the thing I know is that the oil lines are blocked
     
  8. Thanos Stavrou

    Thanos Stavrou New Member

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    Back in town, figured i would start by changing the oil and oil filter as a start. Where can I buy the filter?
    Also can you please tell me if the o-rings of the carb rebuild set that i sent are compatible? If not has anyone found a low-budget carb rebuild set?
    Currently pretty sort on money (forgot to say I'm 15 years old so i don't have my own money).
    Here are some pics of the bike:
     

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  9. minimuttly

    minimuttly Active Member

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    Has that smell of greened fuel got up your nose yet?
    Anyway, you want to see if the rest of the bike is ok before spending money on a turbo? Yes, good idea, but the answer depends on what your intentions for it are - is this going to be an imaculate, shiny example to cherrish foreverer? Or a stripped down hack to learn and pass your test on?
    If you are talking about restoration, the whole cost will be more than a turbo I suspect, so budget for that.
    If it's a hack, clean the carbs, do as @Simmy says, free and make sure both brakes work and take it for a run to test the engine. Then make a decision. It's unlikely the engine is knacked, they just last and last.
    If you're going to use it as a non turbo you might want to rejet those carbs (there is a thread here somewhere about running turbo carbs NA) or change them for Hitachis. Personally I prefer Mikunis, but there is nothing in it.
     
  10. minimuttly

    minimuttly Active Member

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    Couple of things - the scavenge line from the turbo - if you block this is the oil pump going to be damaged?
    Re the carbs, I'm running NA versions (from a 600) of those Mikunis on my 650 maxim, they are very close to correct out of the box - maybe a tad rich (that's a guessbut I only feel it when hot) just off idle, when riding. Would be interesting to note the different jets and needle.
    And of you're going to recommission this, budget for brakes both ends, tyres, electrics, various cables, lights? seat? exhausts and of course turbo. Paint for the panels and frame, and your time of course.
     
  11. minimuttly

    minimuttly Active Member

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    Oh, and the slide springs....
     
  12. Thanos Stavrou

    Thanos Stavrou New Member

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    So yesterday I made progress. I cranked open the carbs but them in some diesel and cleaned them with compressed air.
    But something unfortunate happened. As I was trying to revive the dead fuel pump I plugged it onto the bike and cranked the bike to see if the pump works. After cranking the bike for a little time I let off the start button but the starter was still going. I went ahead and pulled the battery cables and it stopped. It did it one more time and now the bike doesn't give any signs of life. I'm pretty sure it's the starter relay (that little thing next to the battery). My dad had the same problem and it was that thing. What do you think am I right?
     
  13. Simmy

    Simmy Well-Known Member

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    If you’re just trying to run the fuel pump you don’t need to run the starter motor.
    If you have the sidestand employed and the bike in gear, you can press the start button and only the fuel pump will run, nothing else.
    I agree with you that the starter solenoid is the place to start looking.
     
  14. Thanos Stavrou

    Thanos Stavrou New Member

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    So made progress again. Cleaned the crabs, repaired the starter solenoid, put the carbs on the bike and it fired up first try. it idles quite smoothly but shuts off due to starvation. Today I took the oil filter off and I ordered a new one. I am also going to order the carter p74017 fuel pump. I read some posts of seca turbo owners that use it and they say it's alright. I want to thank everyone that has helped so far with this project. That's it for now
     

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