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!!!

 

Absolutely a beautiful creation!!! If Yamaha produced this bike I would buy one.

 

Thank you for your kind words! I wanted to make it look like a stock factory bike. It certainly was an absorbing and fun project. The best part was getting those small, subtle styling parts made like the swing arm covers. I’m also particularly pleased how the XJR tank turned out. I thought it would look too big, but once the seat’s fitted it looks right. I think the whole bike is much more imposing now. A bit beefier. I’m just starting work on another XJ900F, a 1990 model. It will be along similar lines with wire wheels and possibly XJR tank, although to make it easier I might use the original tank. I don’t like the shape of the original tank, so I might make some mock VMAX style air intake scoops to alter how it looks. This time I will go for a silver engine instead of charcoal grey/black. I had in mind style of the XJR in the picture below.

Cheers, Shaun

 

Wow Shaun, that's impressive. I'm mostly a purist but every now and then someone comes along with a well done restomod.......this is definitely one of them!! Looks like a stock bike, the attention to detail is amazing!

 

Cheers for that. Yes, it’s one that can very much divide opinion! Some don’t mind changing the look of a bike, others think they should be as originally intended. I usually only work on bikes that are either complete non-runners or not enough of them left to make it worth returning to original. This bike kind of fell in between. It was fairly complete, but a non-runner! Also, it’s not like the XJ900 is a rarity. There’s so many around, so I guess one or two turned into specials won’t upset the purists. What I didn’t want to do was make yet another cafe racer - I wanted to keep some of the Yamaha heritage and create something that would fool people into thinking it was an original Yamaha model. That’s where the detailing came in. From the bespoke engine and clutch covers designed in ‘Yamaha style’, the use of recognisable Yamaha parts like the rear mudguard and grabrail, designing the XJ900 logo for the alloy badges and even down to having special fork top nuts made with the Yamaha logo etched in, even though the forks are from a Suzuki! I really enjoy doing this kind of thing, though once I’ve done the next one that will be it I think. I’ve taken early retirement so any money I spend on bike building doesn’t get replaced from a salary, and you always spend more on a bike build than the bike is actually worth. But I just do it for the fun of it. It’s an interesting challenge and keeps the brain functioning!

Best wishes
Shaun

 

If that didn't have an XJ engine on there I would think it was one of the modern retro look bikes from a dealer, it really is impressive.

 

Thank you. I think the XJ engine is quite timeless. It’s a good classic looking engine and a very ‘clean’ design. I think I’ve chosen, or had made, parts that complement it. Although I had a good idea in my mind how I wanted the XJ to look it’s not until the tank, seat and exhaust go on at the very end when you know if you’ve made the right choices or not. I was pretty pleased. I don’t know if there’s anything I’d change. Perhaps keeping some form of rear disc brake would have been nice, but I’d have to get a bespoke hub made, although I reckon it might be possible to fit a disc carrier into the drum brake recess. I might do it on the next one, but it would be expensive. A well set up drum should be nearly as good as a disc though.

Incidentally, after I finished the bike I found a photo of the 2025 Honda CB1100 (below). I think they copied my design, even down to the paint scheme!!!! A very spooky coincidence!

Best wishes
Shaun

 

I’ll let you know when I come to sell it!