A cry for help! Fuel lines everywhere question

Hello everyone.

So, we picked up this engine, to use as the power plant for our mini sand rail. We were told it is out of a 1982 Yamaha seca, Non turbo. I belive that makes it an XJ650 motor.

Anyways, the engine came with the wiring harness and everything attached, except air intake, exhaust, batter, frame, tires, gas tank, etc. Basically, just the engine. We are trying to figure out how to fuel the thing. So, the question is, what hose goes to what? I have attached a photo with the different options.

We were told that hoses 1 and 2 get the fuel from the tank. We did this, and fuel started spewing from the holes that have yellow labels. However, with fuel going to hoses 1 and 2, and hose 3 left alone, the engine started and ran. But I personally dont think this is how its supposed to go

Also, I have a suspicion that a Fuel pump is needed somewhere, unless the engine is gravity fed fuel from the tank, which could be possible. So the second question, is, other then exhaust, and something to deliver clean air, what else will be needed to rig the engine to run in our sand rail?

The last question is, have we labled the engine correctly? Is it a XJ650? If so, is it a RJ, Rh, or whatnot?

I have attached another photo of just the engine.

So, 3 questions:

What line goes to where from the drawing we have labeled?
What else is needed to run the engine, other then what is in the photos?
Is it indeed a xj650, and if so, what is the specific synonym for it?

 

Re: A cry for help! (Probably a simple solution)

Chain Drive, Makuni Carbs Thats a XJ550 not XJ650 That engine was made to have intake restriction and exhaust restriction to run right. It will be a major pain to tune to run right on any application but a motorcyle. Good Luck

 

Re: A cry for help! (Probably a simple solution)

I am not sure if I am going to be much help.
The number three is for the main fuel from the gas tank. The fuel is pulled from the tank by vacuum. There isn't a fuel pump. Also the motor will not run unless you have the carbs hooked up to the air box with filter. I will look in my book to see if about the 1 and 2 on your pictures. I think I have a different set of carbs than you do.
Also all the letters mean is the year it was made.

 

Ok, so that would be the reason why we've been confused so far We have been looking at manuals and parts for an xj650. Anyways, are you sure its a 550?

 

Hard to tell from the angle of the photos, but those appear to be XJ1100 or XS1100 carbs.......


Just "across" from the snout of the starter motor (where is goes into the engine case) there is a flat pad that has a series of numbers/letters stamped into it. If you can give us those, we can tell you for sure what it is.

 

650's and 750's came with Hatachi carbs, and were shaft drive. XJ 550's had Makuni carbs and were chain driven. XJ 1100's were shaft drive and had Makuni Carbs. XS 1100's had Chain Drive and Makuni Carbs. Your engine looks small and has chain drive. I'm betting 550 about 98% sure. Ask Big Fitz He's the 550 guy

 

I just looked again and Your clutch is a give away. 550 100% sure now. 1100's you can't see any clutch lever since its under the RH cover.

 

Ok, the number is 4DU-046761

Also, on the side of the carb, is the logo Mikuni. I think this all means that we have an xj600?

Our carb looks just like this one:
http://cgi.ebay.com/ebaymotors/Yamaha-X ... ccessories

It has those little holes in the face that ive drawn yellow arrows to.

 

So basically, we dont know anything about this engine, other then it runs, albeit roughly. It was purchased from some guy on craigslist, who had it listed as an 82 yamaha seca engine. I think he might have been wrong, and it might perhaps be an xj600, instead of an xj650.

Thoughts? This all might be irrelavent, if someone can tell us where to put those tubes

Would more photos be of use?

 

I'm still thinking its a 550.

 

Even tho that one on ebay is listed as a xj600, and its identical to our carb? I guess we could have an xj550, with an xj600 carb on it. And word from chacal, who was going to be able to identify it off the number he requested?




PS, were on page 2 now

 

That is an xj 550 motor, no doubt. #3 is the fuel line, #1 and #2 are vents. Whats the deal with the carb support bracket on the top of the carbs? It is supposed to join all 4 carbs together.


Oh yeah MN-Maxims, xs1100s are shaft driven as well. The only chain driven ones have been converted. An xj1100 is just an xs11 with different body parts, a more complicated electrical system, and yics. All the other motor/drivetrain parts are the same.

 

Well just did alittle digging here and that 4DU number indicates a 1992 XJ600.

 

Look on the block between cylinders 2 and three above the oil filter You will see the cc's embossed in the crankcase also

 

Thanks organized for setting me straight on that 1100 info

 

Ok, so it says 598 cm^3 4BR00, so 600cc. So can we be sure its a 94? I belive that the xj600's were built between 1984 and 1994.

 

You'll need to find a shop manual on that one too new for me. Good Luck

 

Ok, so how do we find out what specific xj600 it is? It appears there are 3 potentials. There are the 1984-1992, labeled xj600. then the 1992-1993, labeled xj600S, then the 1995-1999, labeled xj600N.

Lol, Why did they go and make so many little models? Or is it that there is almost no difference in them, from 1984-1999.

 

oh, and here seems to be a link that has all the yamaha shop manuals on it:

http://manualz.info/paginas/manuals/Yamaha.htm

 

Ok, so does anyone know how we need to rig this up? Do we need a fuel pump, which some models of the xj600's have? The pump im referring to is powerd by some vacuum line of the number 2 intake manifold.

 

Those mikunis should work just fine being gravity fed. Just make sure the tank is higher than the carbs. Fuel supply should be routed to #3 in your picture. #1 and #2 should have hoses attached and be vented to the atmosphere. If fuel comes out of them, the floats are sticking.

 

The fuel tap/petcock is vacuum operated on these 80s vintage bikes. A small spring-loaded diaphragm unit sits inside; when there is sufficient vacuum, it pulls the diaphragm back and allows fuel to flow. The vacuum is supplied by a line going to one of the intake manifolds.

 

in actuality, I don't think this is an 80's motorcycle anymore. Since it is an xj600, I believe it was made somewhere in the range of 1992-1999, specifically in 1995. I'm basing that off our engine model number of 4DU-046761, and the table here:

http://books.google.com/books?id=RthtvM ... t#PPA38,M1

, on page 38. Can anyone confirm if im barking up the right tree?

Anyways, If I am right about this being a 1995 xj600S, the fuel is controlled by a fuel pump, which is driven off a vacuum line that goes to the intake manifold on cylinder no.2. Can anyone confirm? But, I would like to gravity feed the engine, and without the fuel pump to regulate the flow, I think it might flood?

 

Bump. Still looking for answers

 

Did you check out the link mleec321 gave you? Looks like the XJ600 manuals are there. You might be able to figure it out from them...

 

A fuel pump of any sort should move more fuel than gravity feed alone. So id venture to say that you shouldnt have any overfueling problems. Having said that, as long as your float valves are in good shape just make sure the fuel supply is above the carbs and it should work fine. Just hook up the fuel line and vents like I said previously and you will be fine.

 

I do have the manuals for the engine indeed. I am the one who posted the link Im still just trying to get everything figured out, as up till a few days ago, I still thought this was an xj650. But ok, I will try hooking up the fuel in the new way. My next question, is where all do I need to provide clean air to? (as in, a line to the air box) I know theres one that goes to the crank case somewhere. Would that be the hole at the snout of the starter motor?

Also, does anyone have a stock air intake box and exhaust? I had thought I could just make my own intake and exhaust, but after further reading, it sounds as if the carbs would need to be Re-tuned to the new setup, or I would risk hurting my motor.

 

Yes you are correct, the crankcase venthilation hose connects to the airbox. However it is not required and many people either put a small filter on it or just run a longer hose and have it vent under the bike.

Everyone recommends that you use a stock airbox and a stock exhaust system but sometimes those are hard to come by so they get replaced with something else. The bike will run fine on pod air filters and a different exhaust, but tuning is necessary and rejetting may be required.

For right now I would just get some sort of exhaust on it and throw some pods on so you can make sure you dont have any other engine/carb related issues.

 

Mleec here is a LINK to the VIN look up on this site.

 

Thanks TheHound! I checked out that link, but unfortunately, its referring to VIN numbers, which are printed on the frame. Since I have just the engine, that doesn't help too much. Also, it doesn't make any reference to XJ600's.

Im kinda stumped here, trying to come up with a specific year for this engine. I kinda need to know, so I can get the correct parts for it. Any more insight or links would be useful, so I can pinpoint its year, Unless.... Is it possible that any exhaust from any year XJ600 would fit any other XJ600? Would this be true for the airbox as well?

Thanks!

 

mleec this may help, on the motor there is a # this is a shortened vin #.
So if you follow this part of the link, the JYA should not be there, the first three digits should tell you the bike it was originally from 4DU-046761
The 7th should be the year "7"
Question is, is it '87 or '97?

JYA4H7006 -0- -a- -bcdefg

Okay, the next position---the tenth position in the VIN number (designated by the number -0- above) identifies the year of your bike. NOTE: the "year" actually refers to the MODEL YEAR of your bike, and not the year in which it was produced. Since "next year's" models normally are available in dealer showrooms sometime around September of the previous calender year, the model year of the bike and the calender year of a bike's production can differ

 

hrm. Well, if that's the case, my theory of it being an 95 is out the window Is there any other info/photos/ anything I can provide? You know, it has the wiring harness on it still. Does the wiring harness perhaps have some kind of code on it that will let me look it up?

 

Ok, so any more guesses before I tell what it is?

 

Well I steered you alittle wrong.
The number on the motor is a shortened VIN but, after looking at my ride it turns out the digits that are omitted are the positions for the year.
ie. my VIN is JYA5V2009CA002679
The stamp on the motor and frame reads 5V2-002679.
So its the 4th 5th and 6th along with the last six digits.

From Chacals write up, that I linked to, I know that 5V2 is a '82 Seca 650.
So following your link I find that 4DU is an XJ600s.
With the serial number 046761 I find it is the 1660th XJ600SF built in 1994.
It's a canadian bike the link you provided even gives you the VIN for the original bike minus the multipler digit.
Your link has everything that you needed you just didn't know it.
Cheers!

 

Well, maybe, but I called the Yamaha HQ, in California (At least one of their plants). It turns out they purge most of the records, after 10 years. However they were able to look up the code off my engine, and find the bike that was coded before and after my own engine. They were both 95's. So according to the yamaha tech I talked to, I am in possession of a 1995 XJ600. Which is kinda cool, cuz the guy I bought the engine from sold me a 1982 XJ650

Also, all xj600 exhausts and airboxs fit all other xj600 engine, regardless of years. So apparently, my quest to discover what my engine is was pointless after all.

 

Right, it was built in '94, so being a '95 model makes sense.
The VIN would have been JYA4DUN0*RA046761
R='95
I had fun figuring it all out anyway.