A new project, the abandoned xj650RJ

Check to see what the specs are:

1. fork width
2. fork tube diameter
3. diameter of center spindle hole

If those are all the same, it should swap. If not, then you have to look at swapping the whole triple clamp. To do that,, check;
fork width
spindle length
bearing sizes--with that, the 650 will have ball bearings, the 700 would have tapered bearings, so you'd do an upgrade anyway..... If you have a custom bearings place near you, you could get a set ordered up. Tell them the diameters of the top and bottom lands of the spindle, and the diameters of the neck where the races would go.

It's do-able, you just have to do some homework and planning....

If I have time, I'll try to do some comparisons and swaps, but it's gonna take a week or two before I can get to that at the moment.....

dave Fox

 

I do not have a 750 fork to measure it but here is what I've got from the one on the bike right now.



If the 750 fits it might be cheaper and quicker to buy one from a 750 instead of trying to make the current one work.

 

i think i bought an extra set of blinkers when i was buying for my bike also i bought a box of bolts so lmk kno the specs on the bolts you need and i can send them over (thread count bolt size)

 

Myro, thanks a lot for the bolts offer. I know I have broken a few so I will need a few. As soon as I figure out what I need I will let you know

 

the top mount for the 700/X/Virago mount will not work with the 650 forks....the forks are too small of a diameter. I tried them here. I didn't have a triple clamp apart that I could compare widths yet.....

Dave F

 

Thanks a lot for checking them out Dave. I will meet with a friend and get the broken bolts out and make the new dash fit in.

 

So the broken bolts are out and now the dash may need a little mod to bolt it in. The battery trey was hiding in my little shed so I finally found it and went back in place. I also got the exhaust back out to be cleaned and put back in just to test the engine/carbs and see how it runs.

I am sure I will be taking a lot of things apart (again) to take care of the cosmetic stuff, really clean, shine, polish, paint everything once I know it is running.

Fun stuff

 

Lot's of rain this weekend so no time to work, I did make a trip to advance auto and bought new spark plugs.

This is what my driveway looks like right now and has been for the past few months:



Can't wait to get the gauges mounted and move on to the next step.

 

Hey BluesBass.............that's almost like a CHALLENGE. It's almost enough to make ME put up a picture and show him what a real pile of bikes and parts looks like! LOL

Dave F

 

I've been wanting to see your "stash" of bikes.

 

Dave are you kidding me... you can't fit your pile in a picture... you would need an album...

And Eco, you would be in Awe... and feel slightly inadequate... and I haven't seen everything... I have just seen one shed aparently ;-)

 

Today I tested compression on the par's bike engine and were not bad:

C1 - 120
C2 - 140
C3 - 140
C4 - 145

I am thinking about checking valve shims and just "transfer" all the parts bike into the titled frame to keep it all stock and call it a day.

This will be a lot less cumbersome than converting the 650 into a 750. As soon as I have time I will take care of the valve shims (will contact Dave as soon as I have a shopping list) and go from there. This weekend I even stopped by and got brand new spark plugs so this puppy should be up and running before next summer

I really want to see what a pile of bikes look like (not at a junk yard).

 

X2, dave needs to post a pic! But he also needs to learn how to use Photobucket!

 

Ya gotta come to a carb clinic to be allowed to see it......LOL

Dave F

 

It's official, got the title for the 750 on the mail today. i would love to attend a carb clinic and check out the stash since "panorama" does not work on your camera

I think the first day of the carb clinic should be a "swap meet" since I have no bike to ride but plenty to haul :wink:

 

Sure! Have done that, too. Heck, we even had one year where the clinic became known as the Central NY Everything-BUT-Carb Clinic". That year we replaced a coil, worked on front brakes, saw how to disassemble a fork, put on new brake shoes, flushed a tank, replaced a side cover, and did a lot of oil and filter changes but no carb work that year.......

Come on up!

Dave F

 

I wish I could (at leastthis year). I will put it on my calendar/radar and will be there next year. I dont know if i will have something to ride but will be there one way or the other.

 

There have been others that have either trailered bikes in ,or have just driven in. All are accepted. ----Even the guy who rode in on his Harley.

DAve F

ps: in fairness, I must disclose that that guy with the harley happens to have a MaximX that his son rode in on with him.........

 

What about a guy on a Honda, but who owns 2 XJs?

 

Let me think about that............Ok, since I have a '67 Honda 305 Dream apart up in the attic. LOL

Dave F

 

Are you one of those that if your dared you would do it?
I DARE YOU

(i just wanna see it too)

 

I said 'almost'...........

 

Wow, I am impressed with the amount of traffic this for gets once it's riding season. I joined in December and it was pretty slow, other than Dave and master Shifu there were only a few posts here and there. Now I feel lile I really need to get something road ready.

 

Well, Dave teased me with one shot of his stable... All I can say is that the place looks like the Budweiser stables with all the 900's

 

Just for reference I found a JIS screwdriver in the little tool bag in my Subaru today when getting the jack out to change the oil.

 

Today our baby went to bed early so I had a bit of time to work on the parts bike. I was getting ready to check valve shims and as I was loosening up the bolts I heard a bird on the tree next to the bike flipping out, I was curious why this little Carolina Wren was so mad, I found out that she decided to call the airbox home.

There is a nest with 4 little eggs so I finished to loosen up the bolts, looked at the weather forecast and since it is getting pretty dark I have decided to finish up the job tomorrow. I am sure momma Wren will appreciate it.

 

You could try to move the nest.

THOROUGHLY rinse (in hot water) a kitchen towel you don't care about and leave it outside for a day or two, then use it to handle the nest. Move it somewhere not too far away and as sheltered as the airbox if possible. She should find it.

I used to get mouse nests. Even in the garage. Mice peed on my Norton's air filter screen and made it rust. I've learned moth balls aren't just for moths.

 

Looks like you need to get another bike....................

Dave F

 

Thanks for the tip Fitz, this is the parts bike airbox that the PG (previous genius) decided to cut off when he switched to pods. Instead of removing the box he hacked the airbox so now is useless. Once I check the valve shims (I would expect a couple out of spec) I will have to mail them to Dave, get them back and install, that may give the little eggs enough time to hatch and fledglings time to move out.

I already have that 750 offsite, what I need is a shed or a bigger driveway and Invisible paint so my HOA won't see the collection

 

Checking valve clearances does get a lot faster the second time around, the first time took forever so here is what I found:


IN - 0.15 - 0.18 - 0.11 - 0.17

------ 1 ----- 2 ----- 3 -----4

OUT- 0.22 - 0.12 - 0.20 - 0.18

This engine so far is looking a lot better than the other one I checked.

The actual spec is:

Intake: 0.11~0.15mm
Exhaust: 0.16~0.20mm

Now I know which shims to pull and look for replacement.

 

Don't forget to check what shim sizes are in there. You MAY get away with just swapping some around............

Also, I don't know as you're accurate on the .16-.20 for both. I believe it's still .11-.15 for intake and .16-.20 for exhaust. So, where did you get the specs of the same for either side?

Dave F

 

Thanks for the ring Dave, I still have to pull the shims to figure out what I need but first and foremost is to point out that it seems the Hayes manual info is wrong and this is the right info based on the link below where people refer to the Yamaha sticker (manufacturer spec).

Intake: 0.11~0.15mm
Exhaust: 0.16~0.20mm

http://xjbikes.com/Forums/viewtopic/t=7 ... rt=15.html

I will have to double and triple check my sources and will delete de inaccurate information to avoid future confusion.

I wish I could meet you up there for the carb clinic, my doctor would not call me back but Dave called me to let me know that I may be getting inaccurate info. It seems like Dr. Hogfiddle-good (music reference) will have my xj running better than my replaced ACL

 

http://xjbikes.com/Forums/viewtopic/t=3 ... rt=15.html

Here's a link to the forum showing that .11-.15 is correct, NOT .16-.20 and it's probably the same one you just brought up, too.

At any rate, compare your side cover to the one in the pic.

You should be going with the .11-.15 IN and .16-.20 OUT

Dave F

 

Thanks Dave, I will go with that. Worse case scenario I need to get another bike

 

It's not that often we see several valves too loose on the same XJ!

I know it is better to have valves in specs, but I don't know if I would bother changing shims that are too thin like intake #2 and #4 and exhaust #1. The worst that could happen is these valves woudl be more noisy that usual. If you change these shims for thinner ones, you will end up with 0.13 and 0.12 mm for intakes #2 and #4, and 0.17 for exhaust #1, which wouldn't give you much room for eventual wear.

I'd be more concern with intake #3 on the tight side of specs and exhaust #2, definitely too tight.

 

Well you don't want them too loose, either. If they are TOO loose, then the valve doesn't open enough, or long enough. Too TIGHT does the opposite--they don't close all the way, or long enough.

Now, it is also possible....maybe a long shot.....that a previous owner has already done a shim swap, but had actually used the incorrect measurement range to begin with, thinking he was putting it in spec.... that would explain the odd clearances...

But you're right......shims that are too loose are not common.

I had also already sent him a PM regarding that, too

DAve

 

Yes you're right, but it brings the question about how much "looseness" is tolerable even if out of specs? I don't think it makes any sense going one size thinner when an exhaust valve has a 0.21 mm clearance, because it would bring the clearance down to 0.16 mm, on the tight side of specs.

I'd say 0.18 for an intake and 0.23 for an intake is definitey too loose, but if you'd go down one size on valves with clearance like 0.17 intake and 0.22 exhaust and then end up with 0.12 and 0.17 respectively, be prepared check them again soon.

 

.12 for an IN and .17 for an OUT are both in spec. In spec is in spec, and won't need to be checked til next check. Next check doesn't mean they're gonna change by then, either. They might, but then again they might not. That's why it is called an valve clearance CHECK. I wouldn't worry about it. I would be more concerned with the valves being too far open. On the fat side of spec is fine. Way too loose is not fine.

Dave F

 

Makes sense. Thanks for the clarification!

 

Ok, for the pat few days we have had afternoon thunderstorms and this waiting is killing me. I can't wait for the birds in the airbox to hatch and move on. I can leave them alone as long as the weather is good so I can get valve shims out and figure out what I need.

 

You need a garage; or at least a carport. Maybe even just a "tent" canopy like a yard sale or something. And some cheap plastic tarps.

 

...or an understanding mother-in-law, a good neighbor, a couple friends, an attic, a wife who lost track of how many bikes are actually around, AND a bunch of tarps..................................

DAMHIKT----- LOL

(and I only put the canopy up for the carb clinics....though I DID pick up one of the permanent yellow ones earlier this spring, and may actually set it up and use it.........too-----)

Dave

 

IT sounds like the first thing I need is move closer to Master Shifu and a Carb Clinic host with AAA rating like Dave. Or at least to a different place where the HOA would let me pile them up on the yard. I am surprised I have not gotten a letter from my HOA because of the current bikes that are not in working condition.

 

Seriously, consider getting either one of the 10x12 or 12x12 garden sheds from sears or somewhere. An afternoon of bolting it together, and you have a good storage spot. Or, for$200.00 get a 'portable garage" canopy=type thing from Harbor Freight........Or, a smaller lawnmower/utility shed from ShelterLogic or build your own......

Dave F

 

Guys, besides my HOA only allowing one outbuilding, I already have a shed with a table saw, bicycles, lawn mower and cornhole set.

Today I wanted to get he shims out and fifure out what I need but I had to work so I had a bit of time before it got dark.

I got half way and so far I found some pretty large shims one 275 and two 290s.

Here is the killer, one of them seems like it has been moving a bit or it was used at some point in life with the numbers right up. When I found it the numbers were down but here is a picture of what I found:



I will have to use one from the other engine and measure again to figure out what needs to go there.

Oh well, like Dave said it will get done when it gets done.

 

Yup, that's a Y2--. I have a few of them, too. LOL

Anyway, here's what you do......take your clearance measurement, and you're almost set. Do you have a dial or digital caliper? Measure the thickness of the shim, no need to put another in. Just measure what you have there. If you're not able to do that, send it up and I can measure it here. Easy.

PM me, or call or txt.....................

Dave F

 

I sure will send stuff your way, I can't figure out where my digital caliper is to save my life. I found two more with erased numbers. One I can take a guess and it looks like a 285 but not 100% sure. There was one with no numbers at all... this is a bit annoying, but oh well.

Dave, as soon as I have enough zip ties to hold all the valves opened I will send you all the numberless plus what I need to swap.

 

i wouldn't try to hold all the valves open at once.

Dave

 

Ok, so this time measuring and taking valve shims was a lot quicker. I found my digital caliper to measure the shims without numbers. Just to make sure I also double checked to make sure that I didn't write things backwards and yes... I did. I had the intake shims as the exhaust and viceversa when writing things down. So I am glad this is a new habit for me "measure twice, order once".

So here are the numbers "Final answer"

EXHAUST
Clearance: 0.22 ---- 0.12 ---- 0.12 ----0.18
shims: ---- 275 ---- 275 ----- 275 -----280
needs: ----280 ----- 270----- 270 ----- 280

INTAKE
Clearance: 0.15 ----0.18 ---- 0.11 ---- 0.17
shims: -----290 ---- 290 ----- 290 ----- 285
needs: -----290-----295 ------290 ----- 290

SPECS:

Exhaust: 0.16~0.20mm
Intake: 0.11~0.15mm

I will be sending Dave a PM soon with this week's order.

 

Well... after a short brake taking on other small projects and still having to paint my house I am getting back to getting this puppy back on the road. I got shims from Dave and the little wrens have fledge from the nest they built on the butchered airbox.

Now is time to get the new shims in and move forward.