1991 Yamaha XJ900F re-imagined

Hi All

Not sure if this is the right place, but if it's for modifications then I guess it might be, considering what I've done!

Well, it’s finally finished. My re-interpretation of the XJ900F into a ‘modern classic’.

When I first saw an XJ900 back in the late 1980’s I thought it looked great. The thing that struck me most was that big good looking air-cooled, in-line, four cylinder engine. I even didn’t mind the styling, as it was just typical of the time.

Move forward nearly 40 years and I found myself with a “late night bought on a whim from eBay” tired old non-running 1991 example. Actually, to be honest, I bought two!

Now first I must apologise to the purists and those that love the style of the big old XJs. The poor old girl was just ripe for a re-design, so please don’t spit on me if you ever see me in public!!!

Anyway, although I still liked the look of the engine, for me the general styling was now just too dated. The plastic work had taken it’s toll to some extent (and didn’t fit properly), the big clocks were, well, just BIG! The alloy wheels just had to go, along with the fairing, square headlight, massive rear tail light and plastic end cover thing, rotted exhaust, seat and the rather peculiar styled fuel tank.

Having recently rebuilt a 1974 Triumph T150 I had in mind similar retro classic styling for the XJ. I also previously owned the mighty 1700CC VMAX. I loved the styling of this too so wanted to take some of those aspects and incorporate them into the XJ.

But my overriding aim, as with other bikes I’ve built, is to make it look like it could have come direct from the factory, rather than something I’ve cobbled together in the garden shed on a Sunday afternoon!

So, here’s what I did:
Cut the rear frame loop and fitted a deck/bridge to take a VMAX1200 mudguard and tail light plus provide support for a new seat.
Reshaped a VMAX1200 grab rail to fit.
Converted to wire wheels by fitting a modified Yamaha XV650 Dragstar 200mm rear brake drum/hub and for the front using a Suzuki GS/GT/GL hub and Suzuki GS1000 front forks.
Minor modifications were made to the swingarm to facilitate wire wheel conversion.
Front mudguard is GS1000.
Re-positioned the fuel tank mounts on the frame to fit a lovely shaped XJR1200 fuel tank, without the need for tank modifications.
Replaced the large instrument console with an Acewell MA-85 electronic speedo.
Replaced the oil cooler with one from a Suzuki VS1400 Intruder with its pretty chrome surround.
Machined the handlebar mounting serrations from the top yoke and sleeved the mounting holes to fit XV535/XV1100 handlebar risers. This allowed the fitment of conventional handlebars. Also had machined a decorative surround for the ignition switch to replace the original plastic cover.
Made a custom alloy seat base which was professionally upholstered.
Designed new side panels which were 3D printed. To these I added my own design of the XJ900 logo made from water-cut aluminium, which I then polished.
With the original side panels gone I made some alloy end covers to conceal the now exposed and rather ugly looking airbox.
Had made some alloy infills to go behind YSS shock absorbers, plus an alloy infill behind the grab rail which also had my custom logo/badge fitted.
Bespoke alloy VMAX style swingarm mounting point end covers, to replace the nasty tin originals.
Bespoke VMAX style CNC engine end covers and clutch inner cover.
Magura Hymec hydraulic clutch conversion.
Larger front discs, Tokico twin piston callipers and Brembo PS16 front brake master cylinder.
LED headlight and modern Triumph LED indicators.
Additionally to all this I made a new wiring loom, reconditioned the engine, gearbox and clutch with all new bearings and oil seals. Overhauled the differential and had carbs fully reconditioned.
The engine cases were powder coated dark gunmetal grey/black with plum covered covers similar to my VMAX.
Finally I had someone local do an amazing paint job, similar to my VMAX1700.
There are probably loads of other small things I’ve done as well which I just can’t think of off the top of my head.

And hey presto! That’s it!

I’m quite pleased with the way it turned out, pretty much how I originally visualised it. I just need to get an MOT now and start running it in.

I hope you approve!!!

Oh, and remember I said I bought two XJs? Well, that’s the next project sorted!

Best wishes, Shaun

 

@ShaunR. While I really like the original that you started from I think you have done a really nice and respectful job of building this bike. A great deal of time and expense, obviously. Now the important part..... go have fun with it!

 

Really impressed!

 

Really pretty.

 

Very tastefully done. Looks like it could have come out of the factory that way. I like.

 

As I started reading I thought, "Another Sawzall merchant with a half-finished lump."

It's not. It looks bloody good.
Well done.

 

Wow, that's some upgrade!

 

Very nice, just reading and thinking about all the time and effort put into that makes me want to take a nap........

 

Given that you're using GS1000 front end, here's a tip.
Get a GS1100E fender and the internal steel brace that goes with it.
This, combined with the aftermarket brace, gives a front end that goes where you point it.

 

Thanks. Hopefully it will go through the road test OK and then I’ll see how it goes. It should be a bit lighter now without the heavy fairing, alloy wheels and various other bits I removed.

 

Good tip thanks. The GS1000 fender I used did have quite a chunky brace as part of it. Maybe I’ll use a GS1100 one on the other XJ I have languishing in the garage. I need to decide how far I want to go with the styling with that one.

 

Many thanks. The factory look was just what I was after!

 

Cheers for that. The real time spent on it was sorting out how the rear mudguard would fit to give enough tyre clearance, plus designing odd bits like the side covers and various infills. I also had to learn some metal folding and fabrication skills for the alloy seat base and airbox covers. The front forks were just a straight swap as they are 37mm like the Yamaha, so the Suzuki hub slotted straight in. The rear wire wheel conversion took a lot of thought, but the actual machine work to make it fit was negligible in the end. Just needed boring out for extra/deeper bearings, shortening the bearing spacer the corresponding amount, and changing the spline to a male one. Then just enlarge the spindle hole in the brake plate to 17mm. All in all definitely a lot more thinking than doing!!!