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1981 Maxim XJ 650 restore project

Discussion in 'XJ Technical Chat' started by Glen F., May 13, 2019.

  1. Glen F.

    Glen F. Member

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    Hello everyone. I am brand new to this forum, and hoping there is some help for me, because I am not a mechanic, but I would like to get this old beauty back up and running after more than 20 years. First things first, I did everything wrong when I stopped riding the bike. I didn't empty the gas, change the oil, ect.... My first child was being born, and any and all money and care went to him.
    Now that he's an adult,( ya right) I am going to try to restore the bike. I have taken the carbs off the bike and cleaned them, but I broke one of the posts off down towards the base of the carb. Does anyone have any ideas as to how to fix this delema? I'm sure it will be the first of many.
    Thanks for any and all help in advance.

    Glen
     
  2. Ryengoth

    Ryengoth Active Member Premium Member

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    Pics of the carb damage? Nice first name, btw. I'm Glen as well.
     
  3. Glen F.

    Glen F. Member

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    I will send some pics when I'm done work, and thanks for the fast reply!
     
  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    there are a few ways to fix broken float posts. threads are posted someplace including someone who welds them or just get another carb body.
    carb body 1 is unique carb 4 is unique 2 and 3 are interchangeable but the throttle shafts must be correct for position.


    thread to read
    The Information Overload Hour

    and how to clean those carbs
    IN THE CHURCH OF CLEAN
     
  5. Glen F.

    Glen F. Member

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    Here is a pic. I tried some Marine weld, but it didn't work. Hard to rough up the area.
     

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  6. XJ550H

    XJ550H Well-Known Member Premium Member

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    jb weld and such things do not last.
     
  7. Ryengoth

    Ryengoth Active Member Premium Member

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    Since the break is so low it could be TIG welded. Epoxy, alone, won't be a permanent fix.
     
  8. Glen F.

    Glen F. Member

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    What if I was to drill a small hole in the post and the bowl, and insert a pin to keep it in place?
     
  9. XJ550H

    XJ550H Well-Known Member Premium Member

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    you can do that with pressure fit.
     
  10. Ryengoth

    Ryengoth Active Member Premium Member

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    You would have to bisect the break with a diagonal pin, with it secured together in original position. Still it could shift and affect the carb. Personally I would tack it back with my TIG welder. The body needs to be stripped to do that. You will always have to use a post support to reinstall/remove the float pin if you repair it by any means.
     
  11. XJ550H

    XJ550H Well-Known Member Premium Member

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  12. Glen F.

    Glen F. Member

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    Could I drill a hole on both sides of the post diagonally and screw the post to the base with a self taping screw? Just wondering? I can't reinstall yet anyways because I need new gaskets, and the drain screw is really stuck. I don't want to strip the head so I have it soaking in carb cleaner.
     
  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    Last edited: May 13, 2019
  14. XJ550H

    XJ550H Well-Known Member Premium Member

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  15. Ryengoth

    Ryengoth Active Member Premium Member

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    If you have a mill you can drill for a center core pin. Anything else is going to be a hack repair unless it is TIG welded. Try what you feel comfortable doing but be ready to buy a used body. Brazing will require too much general heat on the carb body to be doable.
     
  16. XJ550H

    XJ550H Well-Known Member Premium Member

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  17. Glen F.

    Glen F. Member

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    Do you have any idea where I can get a used one from? I don't trust ebay too much. Never know what you are going to get, and when you are going to get it.
     
  18. XJ550H

    XJ550H Well-Known Member Premium Member

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    post in the wanted section many members here have carb bodies
     
  19. Glen F.

    Glen F. Member

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    Thanks for the info. I have posted, and had a reply! This site is awesome!!!
     
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  20. Glen F.

    Glen F. Member

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    Can't do much until I get a new carb, so I started doing some cleaning. Just used some tinfoil and water. What a difference after 20+ years of sitting.
     

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    Jetfixer likes this.

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