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!

 

Yeah, it was more about the looks. The previous mc unit itself was angled and therfore overall horizontal.

 

Sure like what you've got going on here, I will definately be keeping tabs on your thread for further updates

 

Nothing happened in a while, but tank should be done this week, hoping to have it back by weekend.
I need to put rubber or similar between tank and frame attachment for vibrations. Let me know if you have ideas. I'm currently thinking about using a sliced up fuel hose.


Update a few hours later:
Tank is done. Just received this image.

 

Pipe insulation AKA pool noodles

 

Sheet rubber-- you don't have a lot of room. If you need some, I can cut a few pieces out for you.

Dave F

 

Yeah, should be as flat as possible. Let me Google what exactly it is and let you know

Edit:
Cool, this will work. Never saw this before. I just ordered a small roll. I think I can use it for other stuff too. Thanks for the offer Dave, all set for now.

 

Aaaaand we're back in business... tank arrived today.
Inside coated with caswell, paint job fixed. Lost the petcock o-ring (seal that sits between petcock and tank) in the process, hope to find a replacement tomorrow, else Major Pita will be grounded for another few days. But it's supposed to rain all weekend anyway. I can use the time to put fluid in my front brake.
This bike really taught me how to be patient.
Only crappy thing is that I will be on mini vacation next weekend and will go to Europe for two weeks afterwards. No bike time for a long while.

 

You just need to keep a couple over there, too.....

 

True
They have a lot of bikes, especially scooters, in Paris. Lots of old Yamaha too.
Also spending two days in Corsica. Hope to find a bike rental there as I have almost a full day of downtime. Would be awesome to ride around the island.

 

You know your life is very good if the crappy part is the mini vacation followed by the European vacation. I have a work week followed by ANOTHER WORK WEEK!

 

Nah, Europe is work, unfortunately. Only free day will be half a day in corsica. But right, I shouldn't complain. I'm just getting whiny because I haven't ridden a bike in months.

 

Argh, the petcock has fuel running now, no matter what position. Gee...

 

How frustrating... Did you ever open up it up? I bought my petcock rebuild kit from Len. After a cleaning and rebuild, it was doing the same thing. Len suggested that I pull it apart again and "peen" (for lack of a better word) the metal disc ever so slightly. In other words, find an appropriately sized deep socket and place the rubber diaphragm/disc assembly at the end so that the shaft is inside the socket and disc edge is on the rim of the socket. With a gentle tap of a hammer, I was able to put a slight convex/concave shape in the disc so that it sits in the seat better inside the petcock.

For me, the problem was solved. Also I noticed that for much of my early initiatives, I never had a good amount of fuel in the tank. Giving it a good fill and therefore having more fuel there to release I think helped to get the darn thing seated properly.

 

Petcock was new and worked before I shipped it off with the tank. Haven't taken it apart yet but that was my next step.
Also have some issues filling up the front brake for the first time. Lots of fluid ran through but still have air in there. Need to spend more time on it as well.

 

I think you'd better postpone your trip to Europe....

 

Yeah, seriously. Who knows what else stops working by the time I come back

 

Leave the bike with Matti. Everything will be mine! Er, I mean fine...

 

Matti's trying to become a 'hoarder....

 

Yeah. All I gotta do is toss all my wife's furniture "projects" and gardening crap to the curb, and I'll have space for more motosickle junk.

 

Doesn't work. I cleaned up garage yesterday and put stuff at the curb. 30 mins later it was right outside the front door to be saved.
The idea of controlled fires comes to mind every time she does that.

 

Took it apart, completely dirty with black stuff. Almost looks like they kept it on while cleaning the tank. Don't think that much dirt was in the newly lined tank and only washed out this morning. Cleaning it now and hope for the best.

 

Confirmed... sand or similar in tank that the fuel washed into the petcock. Petcock is clean, now I have to rinse the tank...



This much from just a little bit of fuel

 

Gave it a good water rinse. Now it needs to dry. No riding again for me...

 

Don't ya hate when everything is a boomerang?

 

Yupp

 

Now you'll have water in your gas.....lol

 

This is going to be me this week.

 

Nah, it's cool. I put in a handful of deccasent....

 

I'm just glad I test ran it before hooking it up to the bike. I mean, come on, who would think of sand in a newly lined tank? My guess is sandblasting before the paintjob.
But easier to clean petcock than carbs.

 

Uh--- desiccant