81 xj550 project

Hey, Thanks for that. Yes, I already looked into different petcocks that would fit, but my search is on hold right now because I shipped out my tank a while ago. Once I have it back, I'll check again to make sure I actually had enough fuel in the tank.

 

So, the new brake lever still doesn't fit, even with some mods. Tired of this now and will just order a new set that already comes with shorty lever.

Now... for some reason, I was under the impression that I need a 14mm bore. But I just found Len's list that states my 81 maxim is only 12.7mm.
Could anyone confirm what the correct size is, please?
When I moved houses months ago, I packed up my garage and don't know where the original MC is right now and can't just measure.

 

HCP3014 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, clamp, and piston assembly, ready to install. Hand lever, brake light switch, and mounting hardware are not included, but are available separately. Fits all XJ650 Maxim, XJ650 Midnight Maxim, and 1981 XS1100 Midnight Maxim models. Mounting clamp is included. 14mm piston bore, horizontally tilted down reservoir orientation, towards-the-bike-centerline fluid outlet port.

From Len's catalog.

Gary H.

 

Thanks Gary, but mine is a 550. So I guess it is the smaller one then.
Actually just found my MC but can't get piston out. Completely seized.

 

Ah, the size is actually on the reservoir. It's half of an inch which equals 12.7 mm.
Problem solved

 

Ahhhhh, duuuuuuh! My bad.

Gary H.

 

Don't worry. And thanks for your quick response.

 

I never thought it would be that difficult to find a 12.7mm brake master cylinder that is low profile and already comes with short levers. Been looking for two days now. Sent email to dime city to see if they have anything.

 

After days of searching the internet, I finally ordered a new brake master cylinder assembly including short levers and clutch lever assembly.

Not much update on the tank: it's still with a shop to get the new liner. They had issues getting the old one removed and had to get different chemicals. I hope this is finally getting done this week, and hopefully they can save the paint job. After that, I'll have to think about getting the damaged paint fixed. The shop who has my tank now does paint jobs as well, but it all depends on what needs to be done. Having them redo the entire tank is not an option as they will never match the current color. +/- one coat will mismatch the tail fairing.
It just never ends...

 

Tank update: after they removed the old liner, the area around that little pinhole started to leak really bad. They now have to do some welding.

My paint job is most likely ruined. But hey, at least I will have peace of mind in regards to having a leak free tank. Grrrrr

 

where in NYC are you? the neighborhood looks like bay ridge. Got any recommendations for a good body shop?

 

Forest Hills.
Have not used a body shop yet. What exactly are you looking for/need done? I recently found a nice shop that does a few things in addition to fixing bikes. I used them to set the float height. But that's about all I ever used a bike shop for.

 

I was looking for a shop to strip and paint the gas tank. The original owner did what looks like a bad macco paint job with no clear coat. Paint chips off and it looks like there is a skim of bondo or a really thick primer base. Everything is becoming soft.

 

Oh yeah, finding someone to paint is a bit difficult. The guy who used to do mine no longer has time. Before I found him, I would go to a car body shop and ask there. Some do it, actually. I had some parts painted that way years back.

 

New assembly came today. Not sure yet about color but might look nice. I just couldn't find a style and size like that in black. Will change the reservoir lid though. I'll throw them on over weekend and post pics.

 

Update from the shop: Tank is all welded up and just got the new liner. Has to cure for 24h now then pressure test.
Next up is to figure out getting it repainted. I'll probably have them do it which means I have to ship out my tail fairing for color matching.
It never ends...

 

That is a good thing. Think about what has to happen for it to end....

 

Very true.
Well, once the tank is sorted and I throw on the new brake/ clutch assembly, all that's left to make it ride-able is checking torques. Color tune and other details will be added slowly after that.

 

The shop that sealed my tank is fixing the paint job as well. So that's great news.
Put the new levers on, I think the color will work. Unfortunately, the reservoir is no longer at an angle.

 

That shouldn't be too much an issue...unless you like riding canyons at an angle!