Advice on stripping a frame bare... anybodies input

I am going to be completely stripping my frame, starting tonight after work. Taking the motor out... well, everything attached to the frame is coming off for sandblasting, modifying and painting of the frame. I have never stripped a bike down like this and need any advice I can get. It seems like it shouldn't be too hard... but when something looks easy, it's usually not. So, please, from experience, what are common mistakes, problems you have faced, dos, donts, etc.

 

Get a Haynes and or factory manual for your bike. The Haynes is a little better at step by step dis-assembly/re-assembly instructions than the factory manual. I LOVE my genuine factory manual that I got from Len at xjforever. Great guy, great manual, awesome service. He is local to the site and a great source for parts and knowledge. search on chacal, or xjforever.

Take good quality digital photos of everything you take off. Store assemblies, where possible, and associated screws/nuts/etc. together in zip lock bags. Write on the bag what assembly the fasteners attach to. For larger assemblies use tie wraps to attach the zip locks to the assemblies.

Label both sides of electrical connections with a piece of masking tape on each side of the connector with a legend that makes sure the right plug goes to the right socket.

Have fun!

Loren

 

Ya, I was actually thinking about the picture thing. I am also going to get a few sd cards and video anything really complicated and just store that with the baggies you mentioned.

 

Having done that exact thing, wamaxim is right on the money. It made things easier to put back together for sure. Things I wish I would have done differently? While the engine is out, check for broken bolts that would be easier to remove before the bike is reassembled, as well as checking your neutral switch...didn't realize it was bad until the bike was back together. Now would also be a good time to go over your wiring harness for corroded wiring or modifications to it you might want to make. Good luck and take your time...it'll be worth it in the long run!

 

I'll back up Wamaxim as well. Especially on the manuals.
After blasting be sure to inspect your weld joints for cracks and/or other damage and be sure to get it corrected before proceeding to paint.
I would be sure to use a good primer after you wipe/rinse the whole frame off with lacquer thinner, and remember, thin coats. Get paint over the primer as soon as it has dried according to manufacturer's instructions. I will make a pitch for PJ1 Fast Black Gloss Black, it turns out a beautiful, color correct finish.

 

Ditto on WAMaxim!

Be preparded to replace things that have dry rotted, or heat baked, like wire loom.

Make sure to pop out all the bearings and bearing races too!

Take a lot of pictures, not only for you, but for us as well! We want to see your progress!

Make sure to tape over your manufacturer plate on the steering stem.

Order the parts you will need to replace now, so you will have them when you are starting the rebuild.

I find it easier to give Chacal my credit card number and credit limit and have him fill it up!

(Just kidding, but if I am not monitored by SWMBO, I could easily give Chacal 2 months salary for parts!) He is a fantastic source for XJ parts!

Also, don't forget to sent Robert your TCI so he can refresh it for you. It made a tremendous difference in Rosie's performance. My son says that he has no problems riding with and keeping up with all of his friends who ride newer 650 crotch rockets.

I have to remind him that he is riding a Seca engine that has been tweaked back a little for a cruiser frame. 9 1/2 grand red line??? Awesome!!

Good luck and we are here if you need us! Send pictures!!

 

A good floor jack and an extra pair of hand will REALLY help getting the motor out and back in.

You’ll figure out REAL quick that the XJ___ Maxim part of your XJ550maxim weighs a couple of pounds and the 550 part weighs :wink: 700 :wink: pounds (it really does weigh A LOT).

ab

 

You know, I had a group of XS-ers, who would strip the bike of all they can, then lay the bike on its side, with wood blocks to support where needed, unbolt the motor/tranny, and lift the frame off.

What do you all think about that idea?

 

Home depot or any hardware store sells little sticker to help with marking the wiring, already numbered. Take pictures of cable and harness routing.

I tried just tipping over the frame to drop the engine out of my 750 seca, but when I picked the frame up, the engine came with it! A 550 engine may not be as tight in the craddle.

 

Agree with what everyone else is saying. Definitely take pics as you go - I played around with the wiring/cable routing for a bit before getting it right. Wish I would have protected the paint by wrapping it in cardboard before putting the engine back in - got a few small scratches to show for it.

 

Hi ! I recently stripped the frame to bare metal and had it powdercoated black. I removed and installed the motor with the frame on its side using a heavy strap and a hoist positioning the frame as I lowered the motor into it and was surprised how easy it made it. Make sure you protect the underside of the frame from scratches using a old quilt or something very soft and dense enough to protect the finish. . I used a aircraft paint remover and a fine wire brush on a drill to achieve a smooth finish and to get to welds that were in ackward locations ! HOPE THIS HELPS & GOOD LUCK ! DON