1982 XJ650 Maxim Build

So I thought I'd start a build thread since I started the disassembly. I got the bike home today and parked in its spot for the winter. I pulled the seat and tank off and connected a new battery to test some things out. Starter works, motor turns over, turn signals and brake lights work, headlights dead.

Here is the bikes condition when I got it, I posted these in my intro thread but just re-posting in the build thread. It's got just over 17K miles and cosmetically in pretty bad shape. Also I think the front caliper may be sticking and it was a pita to move and on the snow the front wheel was locked, I could get it to roll on concrete but it was a hard push.



And it's home.



Now I have to wait for the guy to get back to us about the title. This was a friend of my fathers who passed away and his son said we could have it, now were just waiting and hoping he gets back with us with the title before I go any further with putting money into it. So hopefully this will be a build thread, I may have to by a frame with a title and swap everything over.

Still debating on whether I want to completely disassemble to powder coat the frame or just leave it as is. It has some rust spots where the paint has flaked off. If I do decide to do a total disassembly it will be my first.

 

If no title shows up there is always Vermont.

 

Not familiar with Vermont.

 

Saw you or your sons post about this bike earlier. Not a bad starting point. It may look rough but it's complete and unmolested overall. I have the same bike and it is a great rider when running perfect. See link in my sig. Proof of ownership/ability to get a title or registration is no 1 for sure.

 

You can register in Vermont via mail, no residency needed. The Vermont registration also serves as proof of ownership. Since Vermont does not issue titles for vehicles more than 25 years old, you can get a title in your home state by using the Vermont registration as proof of ownership. Vermont will require a VIN inspection report from a LEO, and a bill of sale.

 

Most all of my frame surface rust is located around the swing arm and the swing arm pivot section of the frame. How difficult is it to remove the swing arm on these bikes? I may just try pulling the swing arm re-finishing it and doing the spots of the main frame around there without complete disassembly. I'd like to have this running and ride-able by spring/summer since it's the only bike I have now. Well I guess that still pivots on getting the title. If I do a complete tear down to bare frame I don't see it being ridden this year.

Could always just get it ride-able then tear it down next winter to re-finish the frame.

 

Swingarm removal.

1. Remove the rear wheel

2. Remove the final drive, and driveshaft.

2 A. Peel the u-joint gator away from the swingarm.

3. Pop the round swingarm bolt covers off of the frame.

4. Unstake the retaining washers.

5. Unscrew the swingarm retaining bolts.

6. Remove swingarm.

 

Thanks K-moe doesn't sound too bad.

I went ahead and did some more disassembly today. Pulled the tank, airbox cover, filter (looks brand new) and removed the carbs. Hardest part of removing the carbs was pushing the boots back into the airbox.

Also I'm changing over to Flickr as I'm tired of how slow photobucket is.

IMG_1314 by Justin Schwab, on Flickr

IMG_1315 by Justin Schwab, on Flickr

IMG_1311 by Justin Schwab, on Flickr

IMG_1308 by Justin Schwab, on Flickr

 

+1 on Photobucket - it is painfully slow.

Remember JIS screws on those carbs NOT Phillip's, also a good idea for the slotted screws/ jets to customize a few flat screwdrivers for a 'perfect fit'.

 

Thanks, but I'm pretty sure I'll be sending the carbs to hogfiddles for the carb rebuild.

 

That is an excellent choice, he will make them brilliant both in appearance and functionality.p
However do not be intimidated by the xperience of tackling the job yourself. Lots of digital pics, sketches and notes (plus asking questions here) and just about anyone can do it.

I did it, and I did things wrong, but people here straightened out my mistakes and in private circles I tell others that I and I alone rebuilt my carbs!

 

ALL the crosshead screws on the machine are JIS.

 

I may try the clean and rebuild myself after today. I got a lovely surprise on my way home from work, my sunroof in the car just decided to shatter for no reason. Called the stealership and its almost $500 for the new glass. Gonna try and find a junkyard sunroof. So I got that going, plus it's supposed to rain here for the next 4 days.

 

Cleaned off my workbench in the basement and moved the carbs and tank inside. Pulled the emblems, petcock,and gas cap off the tank. It's pretty rusted and I'm going to clean it in my buddies electrolysis tank. Also removed the dreaded Stealers sticker.

IMG_1327 by Justin Schwab, on Flickr

 

So I bought a Ultrasonic Cleaner and got a few parts in today including my JIS screwdrivers, so now I can start re-building things. I went through cleaned and rebuilt the petcock and started on the gas cap but Im gonna need to get a new gasket for the cap so I can put it back together yet.

Ultrasonic Cleaner:
IMG_1347 by Justin Schwab, on Flickr
IMG_1348 by Justin Schwab, on Flickr

Fuel Petcock before:
IMG_1336 by Justin Schwab, on Flickr
IMG_1335 by Justin Schwab, on Flickr
IMG_1342 by Justin Schwab, on Flickr
IMG_1356 by Justin Schwab, on Flickr

Fuel Petcock after cleaning and rebuild:
IMG_1357 by Justin Schwab, on Flickr
IMG_1358 by Justin Schwab, on Flickr
IMG_1359 by Justin Schwab, on Flickr

 

Be sure to polish the seats on the petcock.

Rebuilding the Yamaha Vacuum Fuel Valve w/pics

Gas cap rebuild in case you haven't found it yet.

Gas cap repair

 

+1. I skipped when I did mine and it leaked. Looks good so far!

 

Yeah, I didn't do that, kinda jumped into this one blind and didn't look for a how to on rebuilding the petcock. So you think pulling it back apart will mess up the seals, should I order another rebuild kit?

 

You should be good to pull apart now, the gaskets will only start sticking after time. I redid mine after using it with no issue. Easier now then after you get bike together.

 

Re-did the petcock this evening polishing the valve seat.

Also a present arrived from chacal, my deluxe carb rebuild kit. So I started taking them apart. I have a carb question. Does the brass piece behind my big finger come out on the carbs? It's spinning freely in the carb body and looks to be connected through to the throat but it don't come out.

IMG_1397 by Justin Schwab, on Flickr


Here's the lovely shade of neon green of my carbs.

IMG_1371 by Justin Schwab, on Flickr

IMG_1373 by Justin Schwab, on Flickr