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82' xj750 maxim repairs.

Discussion in 'XJ Technical Chat' started by Nicholas smith, Jul 11, 2019 at 4:59 PM.

  1. Nicholas smith

    Nicholas smith New Member Premium Member

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    I picked up this "new to me" 1982 xj750 off marketplace the other day, no battery, no starter and 60k km, but i bump started it in the driveway and it ran fine, and idle well also. Put it in the truck and brought it home. Besides it needing a battery and a starter.. it also didn't have the gauge cluster hooked up, rpm needle was broke, turn signals were taped on the front fork, the rear turn signals were falling off.. you know all the typical things.. seat was just sitting there...

    The previous owner before me had installed the stock bars but upside down.. making the turning radius of this bike tripple id bet...

    For now ive stripped the old bars, risers, ect.. off the tripple tree and thanks to a thread on here i ordered up some 1981 virago risers and ill use those for a full bar. Tanks off to get some work done to it, had a few bad dents, also took the batt box fairings off too. Did an oil change, filter change, going to go through the wiring and fix some unnecessary crimped connections, that seem to be everywhere...

    Had some tail end turn signals dropped off so ive got those mocked for now. Thinking about how to close up these holes on the fender, if its worth tacking some steel in the holes or just getting a different rear fender. The risers are in the mail, bars are in the mail ect...

    This is my first xj750 and my first project bike. My other build (4x4) is at a halt due to not having a garage , but the bike fits fine in my basement so thats a win! Im also very happy this forum uses the same format as my other project forum, and the how to video section is an awesome addition!


    This is how i picked it up the other day, also the advertised photo.
    Screenshot_20190708-162131.png
     
    Last edited: Jul 14, 2019 at 2:49 AM
  2. Nicholas smith

    Nicholas smith New Member Premium Member

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    Also took some photos of the starter taken apart, ive never rebuilt one but it looks like it shouldnt be too hard. Just some brushes and o rings and a crazy good cleaning might do it... Ill do some research, i think i saw a video in the how to section if i decide to tackle it myself.

    IMG_20190710_171055.jpg IMG_20190710_171103.jpg IMG_20190710_171110.jpg
     
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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    not much of a fender on the front of it

    and a big wtf on the handle bars
     
  4. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    It's easy to get the starter clocked wrong upon reassembly. Do that and it will turn in the wrong direction.
    Replacing your starter motor brushes w/ pics
     
  5. Nicholas smith

    Nicholas smith New Member Premium Member

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    i know right. the bars are ridiculous... its definitely a few peoples aborted projects in one... bars should be here next week, along with the risers.
     
  6. Nicholas smith

    Nicholas smith New Member Premium Member

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    i dropped it off at a shop for a quote, if its not too bad ill probably just have them do it and get a warranty. Id like to get out and ride for the rest of the season asap.
     
  7. Nicholas smith

    Nicholas smith New Member Premium Member

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    still havent gotten the starter quote but will shortly this week, I fixed the two big dents the P.O put in the tank so those bars to fit better upside down... and some other minor stuff with the tank. Cleaned the valve body and it all seemed good. Im no body man in anyway but it came out alot better than it was so thats all that matters to me.

    IMG_20190711_091536.jpg IMG_20190711_091540.jpg IMG_20190711_110807.jpg IMG_20190711_160340.jpg IMG_20190712_121412.jpg

    All the turn signals were electrical taped on the bike and shot , replaced them with LEDs not really thinking much of it, and now im looking for a relay because my turn signals stay solid, potentially one i can ground the third prong to the bike , as ive read it keeps the auto cancelling portion alive, but ive tested mine and i dont think id trust them anyway. I read if i wanted to loose that feature i could just use a 2 prong flasher relay. The one someone suggested in that thread was a bussman 552, is that because its a good brand, or are 12v flasher relays really that different from one to the other ( serious question as i dont know much about relay specifics ).

    Ordered a tail light and im sure ill have some wiring to mess with to make it work but thats just the way she goes..
    Excited for time this winter to eliminate the cluster and all of that birds nest of plastic up front and free of some space, and get the harness all tucked into the frame more.

    Waiting on parts still, also this factory seat is all broken, loose , and held on with hopes and dreams....Probably going to order a cheaper simple seat and just make a bracket for it, tacked to the frame for now, so i can atleast get out riding before winter comes..

    how the bike sits now.

    IMG_20190712_224834.jpg IMG_20190713_114300_335.jpg
     
  8. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    The Yamha system is a bit propretary, so the type of signal relay you use is really important. Grounding the third leg of the OEM relay does nothing of value, and the only way to retain the auto-cancel with LED lights is to use two relays. A two-prong relay has to be of the correct type internally or the system won't work at all, which is why the Bussman 552 is suggested (there are other relays that work, it's jut that one happens to be commonly available).

    Link to the 2-relay solution.
     
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  9. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I'd like to add that you could just install load resistors, but that defeats the main advantage od LED lights.
     
  10. Nicholas smith

    Nicholas smith New Member Premium Member

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    Thanks for the help and link. I purchased a 2 prong LED flasher relay ( with a built in resistor ) at the local store because i couldnt find a bussman552 at the parts store, I installed it, now i get one flash and then nothing. I dont have my front signals hooked up yet so im hoping that has something to do with it but they will be delivered today. Once installed later on, if they still flash once and stop, i will order the bussman 552 relay, they are only a couple bucks on rock auto and shipping isnt bad.

    IMG_20190714_104533.jpg IMG_20190714_104542.jpg IMG_20190714_104546.jpg


    One of the next things on the list was a working horn, i tested power at the horns with a test light, good. tested the switch wire good, narrowed it down to the switch, once i took it out i figured itd be the problem. Simple cleaning the switch contacts and the ground solved the problem.

    IMG_20190714_120853.jpg IMG_20190714_120857.jpg

    The clutch switch was broken in the handlebar lever slot. Switch works, but tabs are broken off... so when you pull the lever it shoots out of the housing.. I will order another one of these , but for now i just cut the wires after the connector so i dont loose it, and married them for now with heat shrink, so the bike should start while im waiting on parts like that.


    IMG_20190714_123345.jpg IMG_20190714_123537.jpg
     
  11. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    You won't need the clutch switch unless you want to start it while in gear. It's safer to just leave it unplugged (in the headlight bucket). The new switch comes prewired, and juat plugs into the harness.
     
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  12. Nicholas smith

    Nicholas smith New Member Premium Member

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    Installed front turn signals and got lucky with the relay. Works, has proper timing for the flash, and the auto cancel for turning left works but not right... thinking it a switch issue now. Either way, that gets one thing off the list for now.
     
  13. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    That shouldn't be affected by the switch position. Without the factory relay, or the 2-relay modification, the auto cancel shouldn't work at all. It can't interrupt the non-OEM relay to make it stop flashing.
     
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