1982 XJ650J chopper project

This is a project that my sons and I started together. It's a 1982 Yamaha Maxim XJ650J. I'm trying to document it in pictures, so I might be able to help someone else with the courage to start on their own. I've been riding since I was 15, (41 now) and have *never* removed an engine block from a frame.. until now.. Thanks people at XJ Bikes.. I wouldn't have started without seeing you go first. So, here it is..
Enjoy!

 

The intake manifolds look a little rough.

 

more cracked intake manifolds

 

wheels and bars off.

 

wheel, back fender off

 

getting there

 

time to pull the carbs!

 

The carbs look pretty good inside, but they're *horrible* outside..
I'm gonna try the lemon juice bath I've read about for them.
Anyone ever try soaking their carbs in lemon juice? Does this actually work?

 

grungy carb hats

 

time to remove the { intake manifolds? | carb holders? | intake boots? }

Does ANYONE know what these are properly called?

ALSO- does anyone have access to a TourMax parts number list?
I can't seem to find one online.

 

swingarm off, harness off, headlight off, engine OUT!
I'm gonna leave the forks on for mock-up, and next comes the fun part.
Cutting, welding, grinding, sanding, priming, and painting.
suggestions? comments? This is our first bike build, so we're open.
Thanks!

 

Maxim-in-a-box?

 

More to come, we're busy with the carbs, wheels, and swingarm cleaning atm.

 

Welcome aboard! It is VERY refreshing to see someone come in to the forums, look around.......and say "I'm jumping right in and am not afraid to do so"! Yeah, you may be nervous, and have questions......that's GOOD! That's also why YOU're here, and why WE're here. You'll be fine, and you're gonna end up with a bike that you will be so incredibly proud of...........and so will we.

Again, glad you're here.

Hey, when you get to putting things back together, don't forget to check valve shim clearances and if you need to swap some out, let me know......I have a shim pool available.

Dave Fox

 

another member whose bike I somewhat expect to come across this summer in mn. starting off nicely!

 

Hi Dave,
We haven't cracked the block open yet, but thank you for the offer! I'm hoping that the inside of the engine looks as good as the carbs did on the inside, but I kinda doubt it.

 

Welcome Agree with Dave it's good to see someone getting stuck into it. How come you're stripping the engine though, is there a fault you know about?

Just wondering because generally if the compressions are good these motors are very, very tough & you may be throwing a lot of money into a sound unit when you could just set the valves up, add fresh oil/filter & run it.

Again welcome, I trust I don't need to warn you about brakes & tires but all the same please have a look at BigFitz's rear brake shoe failure thread, link is in my signature. Thanks

 

Just cleaning it up, mainly.. It's filthy.. It ran perfectly before I started breaking it down. I think the farthest I may go into the engine is replacing the valve cover gasket, and removing the starter to clean it/around it. The carbs are getting new float bowl gaskets, internals cleaned up, and new intake manifolds and gaskets. I've ordered new front and rear brake pads/shoes, and new tires front and rear. Fork seals are ordered, too. Thanks for the input guys.. Nice to not feel alone cutting up something already so cool..

 

Good stuff, yeah if it ran well before I'd suggest just replacing the valve cover gasket (and "donut" pressure-washers for the bolts too, they provide the clamping force for the cover not the actual tightness of the bolts) and checking/setting valve clearances while you're in there (it very often gets skipped as people think it's hard work with being shims, when it's simplicity itself).

Oh, and the good clean up you mentioned too!

 

Here they are all cleaned up.. Much better.. A little pitted, but they are 31 years old.. Amazing what Coca-Cola and crumpled up aluminum foil will do to rust on chrome.. Gonna have to run them over the buffing wheel once or twice..