CDI cover repair

Hello, all. Short-time member, first-time post.

I've ridden two bikes in my life: 1978 KZ650 B2 (from '91-'93), and 1983 XJ750 MK (now). I only did plug/oil/filter changes, and chain adjustment on the KZ, leaving all else to the shop. With my recent purchase, I'm eager to learn more intermediate maintenance. On day two of my ownership, due to rider error, I gave myself a chance to do a cosmetic repair.

The CDI (a.k.a. "Brain Box", ECM, ECU) cover was damaged in when I tried to lean my XJ as far to the right as my old KZ650 while executing an easy, low-speed turn onto a side-street. Somehow before I bailed, I hit the kill switch...

At the scene, I was embarrassed and uninjured. At home, I was disappointed that I'd ditched my XJ -- it was relatively damage-free on the day bought it.

The right turn signal lens was shattered; the brake lever had a flat spot ground into it; the CDI cover had a piece broken out of the lower right quadrant, and the tail-pipe was slightly flattened at the trailing edge.

Enough hot air from me on that. What follows is the repair to the CDI cover and a shot of the repaired brake lever.

 

VERY NICE work! And super cheap too. A lever is what $8 or so? How much is your time worth? I like the way the cover turned out but I'd still have sprung for a replacement. Of course the up side is now your bike weights a bit less...might go faster or further on a tank of fuel.

 

Thanks, Robert. I would rather have replaced the cover too, but being on parental leave allows me to pursue small projects while my son sleeps. It was a first-time repair of that sort for me with J-B Weld, and it was (relatively) rewarding. However, I'll always know that there's a patch under that semi-gloss.

I'm planning to file-off all the cooling fins and rebuild them with cold weld to save a little more weight. *snicker*

I'm back to work in a week, so my time will be more precious, and parts-sellers will start getting my dough. Cheers.

 

thats a realy nice job on cover,and thanks for the plumbers putty idea,I'm sure I'll use that one of these days

 

Props!

Looks cool.

 

my maxim had a hole punched in the clutch cover by the P.O once removed (the 2nd owner, or in other words the guy before the guy I bought it from)...

MY P.O. put JB weld in it (right behind the brake pedal) and it started leaking. i had it welded up and then filed it down, and started the polishing...

yours looks really good. youve got the advantage of not needing it to be oil tight...

d

 

Thanks, Ass.Fault.

You too, OldGrunt. You know how it goes with things like plumber's putty -- you buy it, use it once and it sits... waiting...

Cheers.

 

Very nice job. I'll have to remember this trick in case I ever... well, let's just hope I never need to use it.