1982 XJ650 stock to bobber project - on a budget

I've been working on it a lot lately, just havent had too much time to post. So this will have a few changes.

I picked up these tail lights at the local truck stop for only 4 bucks each. They are just what I was looking for

 

Here's some paint action going on. Semi flat black. I rattle canned the whole thing. Loud and dirty, that's how a like it!


The green is just self etching primer. Although it kind of did inspire me. I like the army green look. Maybe the next one I do will be a US Army theme....

I let the primer get all over the tires. I tried to mask them off but the tape would only stick to the lettering. But after the paint dried, it rubbed right off the rubber with a little effort. Paint is not made to stick to rubber, you know.

 

I got it back together. Here's some pics.

If anyone has any suggestions, lets hear them.
























I have already started making changes since these pictures were taken a few days ago.

The exhaust doesn't appear the way I wanted it to, just doesnt go with the whole bobber theme. So I chopped it off just in front of the foot controls. I then cut it after the first bend off the cylinder head, rotated it 25 degrees out, and rewelded it. Black header wrap is on the way also.

I also bobbed the front fender. I removed 2 1/4" front and rear, and dropped it 3/4". But I didnt just wack the front and rear of the fender off, I sectioned bits and pieces out to keep the stock lines on all the edges. Pictures of that to come later....

I also put plugs where the front turn signals used to be and took 2 inches of total width out of the handlebars.

The gauges may come off after I get it running just right. I'm still waiting on some jets and a lower carb rebuild kit I ordered from Chacal a few days ago. BTW, thanks for sending me all the parts Len!!!!

 

Looking good! Stuff always looks great when it is in a gloss black. The tail lights look awesome!

 

If you still have the seat I'd love to take it off your hands

 

Love it!

 

I'm diggin it! Offer still stands...I'll send you a set of blue dots for free if you want them.

Dan

 

I like it!!!!!! Just wondering where did you get those pod filters? how much? & did you have to re jet the carbs?

 

Is that seat angle useable? Looks like you'd slip off it onto the guard (?)

Nice work BTW

 

Hillsy

Yeah, the seat is something that might be changed soon. I'm not sure. I need to ride it a little more before I make a decision. I am only 5' 6" and 160 lbs with a little butt, so it's not a big deal to me. But to someone of larger stature, it could be a problem. But I need to put some more miles on it before I make that decision.




XJJoe

I got them on line from some random supplier. I just typed in Unifilter PK-82. I first ordered them from the Yamaha dealer out of thier catalog at the parts counter. But the info was incorrect for this model bike and they sent the PK-92 with a larger diameter - didnt fit on the carbs. So the dealer too the 92's back, but said they could not get the 82's. (whatever...) So I just searched online myself. Kinda pricey at 75 bucks for 4 of them.




MaximXJ

Unfortunatly, I sold the seat a few weeks ago to another member of XJbikes.com. Sorry




Danno

I'll take you up on that!!!

Christian Rath
20 Brickyard Dr. Apt D16
Bloomington, IL
61704

Let me know if you want me to paypal you some money for shipping. Thanks, props to you for helping out

 

No worries. Love what you've done to the Maxim!

Look forward to seeing more progress

P.S. Get those side covers on the engine polished up!

 

Looking Good Crath !!!! Think you nailed it with this one !!!

Hats off to Dan for being a great guy !!! He came to my rescue when I broke an exhaust stud as well ! 8)

Thanks again Dan!!


Keep up the great work Crath, can't wait to see your bike apon completion !

Cheesy!

 

If I were 20 years younger,I would be a broken stud. Currently,I am just broke.Glad I could help you out,Cheesy!

 

freakin awesome.

 

Thanks for the help and comments guys, much appreciated!! I got my stage 3 jet kit and lower carb rebuild kit in today from Chacal. I started cleaning the carbs and will be reassembling them tomorrow.

I also rebuilt the brake master cylinder today.

I have a question on that if anyone can help me. After rebuild, do you have to 'bench' bleed the master cylinder as you would on a car? Because after I rebuilt it and filled the reservoir with fluid, I still didnt get any fluid/pressure to the brake line at the caliper. I disconnected the line at the caliper, and nothing... any suggestions???

 

With a helper - put a wrench on the banjo bolt at the master cylinder. Wrap a rag around the banjo/wrench/brake line. Perform normal bleeding procedure (pump, pump, hold, open bleeder, close bleeder, repeat). A lot of times air will get trapped in the banjo fitting on the brake line. They make banjo bolts with a bleeder built in specifically for this purpose.

 

I still havent gotten to the brakes. I got too anxious and finished the front fender and exhaust first. I also rejettted the carbs, but they still need to be syched. It runs much better now. Also a very different sound with the scavenger exhaust. In a wierd way, I like it. It does blow a little on your feet, but it hasnt been a problem yet. I rode around town tonight with ease.

I took 2 1/4" out of each side of the fender and dropped it down 3/4". I took it out of the middle to keep the stock lines on the fender lip.

 

Wow you guys really make me want to go out and buy a welder and paintgun, right now. My wife thinks my bike is cool stock. (hahaha) Keep up the good work excellent looking ride man!

 

Crath

I was wondering if got that seat sold. If you didn't let me know, I need one bad.
Thanks
The Buff

 

Also while I'm at it.
Are you still going to use the original mufflers? If not I'm looking for those too.
Thanks
The Buff

 

awesome I am building one right now. How i found your post was searching for bobber hard tails with swing arm. I had the same plan drawn up and some buddys told me it was a bad idea to leave that swing arm in. But it looks like it worked out great for you so i am for sure going to go about it this way for the simple fact as the rear end will stay square and it is one less thing to deal with. The bike looks great man

 

Great Buffalo

I sold the seat already, sorry. I also cut off and removed the stock mufflers. But they werent in real good shape anyways. They got thrown away.

Caliber

I havent had any problems with this setup. I would recommend it if you are going hardtail. It is kind of difficult to remove the rear wheel, but not impossible.

 

I did some cruising today, about 100 miles all together. Picture and video

I still need to sync the carbs, but it runs really well

 

Looks and sounds great!!!

It's weird for me to see someone riding without a helmet (Missouri laws).

 

Sweet picture!

+1 on looking / sounding great!

 

YA MAN THATS SICK

 

Great job on the bike. Absolutely killer. Earlier in this thread, kevineleven mentioned something about the shaft angle. Should it be level, or is there a certain degree it should be at?

 

BADA$$!!! Ur bike looks n sounds SWEET!!! :twisted:

 

Thanks for all the comments guys. I have really enjoyed this bike, both building and riding. I have put about 700 miles on it now since completion. I've been riding it everywhere as much as I can. I havent gone on any long distances, just around town and country roads. I put it in the bed of my truck and drove to St. Louis last weekend. I had a freakin blast riding in the city. People were 'rubber necking' like crazy - some very funny looks from most.

I havent had any problems with the driveshaft angles either. We shall see what the future brings though.

No changes lately either. I am pretty much satisfied with it for the time being. I did replace the ignition coils, thanks Chacal!!!

It did get rained on for a day and night strait though. Because of the pod filters, water got in the carb floats. I had to drain them and blow the motor out a bit to get it running right again That was a pain in the ass to diagnose.

I am in the process of looking for an Yamaha XS or twin cylinder Honda CB for my next project if anyone knows were to find one.

 

I'll tell ya what... whenever my dad gets around to putting his old wing back togeather, I'll sell you my xs400.... no idea when that will be though.

 

Well let me know, I am in the market right now for another one. I already have a friend who is flashing money in my face for this XJ650. But I like it so much, I dont want to sell it until I have another one to do the same things with. I just dont want to be without an old bike now, lol. Just let me know when you are ready to get rid of it.

 

I'll start harassing my dad about the goldwing. I REALLY want it for commuting with the wife, and she'd love for me NOT to have 2 bikes.. hahaha

 

Hey,crath,too bad you're so far away from New York. I have 3 CB 450 DOHCs,and another on the way. You can find them pretty cheap around here.The last one I bought is complete and original (9,000 original miles),but has a locked up motor. Still not a bad deal for $81!

 

I am fighting the urge to be a gear-nazi (helmet, gloves, jacket)

Must-bite-tongue...

Good work on the bike, it must be as loud as hell in real life.

 

You can't help it spinalator, it's bred into you by an overzealous, totalitarian, bureaucratic government that doesn't trust its citizens to make any decisions for themselves. Now we can't even ride a pedal bike without a helmet.

It's truly sad.

And, oh yeah.... The Bike Rocks!!!

 

Maybe, but that doesn't make it a bad idea to wear those things. I'm sure he's talking about person-to-person advice, not extra laws.

And, person to person, if you're interested in data, check out the Hurt report. If that doesn't convince you to wear a helmet and a jacket, then nothing will. Not only are you more likely to get hurt in an accident in which you are not wearing gear, you are more likely to get into an accident in the first place.

So, Spinalator, looks like I did the ranting for you...but I will agree that we don't need more laws, we need more education.

 

What are the potential problems? Does the driveshaft have to be parallel to the ground or and a certain angle? I really want to try something similar, but that's the one bit of info I need to start. :?

 

NO certain angle, but you dont want to lower (or raise) the bike so much that it puts the universal at too steep of a bend. They are designed to move around, but too much angle and things will bind up. Mine is lowered 3 1/2 inches and is fine. Crath says his 6inch drop is alright too. I think you'll be alright as long as you don't go crazy with youe height change, but it's something to be aware of. I thought his 6 inch drop would be pushing it, but apparently it's not.

 

Thanks kevineleven, that's the exact information I was looking for. It's the little details like that can make a mod like this really good or really bad. Thanks again for the valuable info!

 

Gorgeous.

 

Keep in mind guys, I have only put about 600 or 700 miles on the bike at this time.

 

The shaft looks pretty straight in the pics... well... at least the shaft housing.

 

If it's anything like a driveshaft on a car, the main concern would be the operating angles of the u-joints. I am not sure what the maximum allowable operating angle is on a motorcycle like this. I would also be concerned about pushing or pulling the driveshaft to close or far away from the transmission output shaft. This could cause damage to the internal components of the transmission (by pushing in) or pull the driveshaft out (by pulling out).

Whether or not the driveshaft is "level" to the ground is not important

 

In any event, hope it all works out.
Bike looks excellent. Would hate to see it get messed up b/c of the shaft angle.

 

Great looking bike the only thing I can suggest is to either black out most of the motor or polish it up. Bioklean makes some nice stuff for cleaning and polishing aluminum thier polish takes almost no effort just light buffing to bring out a shine. The stuff is used more for sleds than bikes but works well.

 

I may do something like that.. black the motor out. But I am going to wait until the winter time before I tear it back down. I've been having a lot of fun riding it every day it's nice out.

I finally got my tags in today. "RELAXD".... in reference to the car club I am in - ///Relaxed Atmosphere.



And another pic from the Eat Rite in just on the edge of down town St. Louis.

 

Man, that's one of the hottest xj's i've ever seen.... period!

Your bike motivated me to buy a 650. I am working on the frame now.

Here is my progress page.

http://www.bobbyhancock.com/Wilma

My site is simple, just like I want my bike. Chacal is hooking me up with tons of parts, he is a killer person to work with!

More to come!

 

Mate as a visual statement that bike looks great but with those pipes I'm so glad I'm not your neighbour.But she really does look good.

 

haha, that's funny you say that. All my neighbors complain all the time!!

 

I have the same bike. And I have two questions. That have not been asked yet.
1) how long did it take?
2) what was the cost? You say budget, but that could mean a lot of things.