Biggo,s Covid XJ900f Rebuild

The old 900 still looks good compared with the newer stuff. Well done mate.

 

I like bikes where the engine is not covered with fairings, they look good and there is ease of access for maintenance. .

 

A local guy made me a nice sheepskin cover for the XJ Very comfy had one on my FJ1200 a few years ago .

 

Done just over 12000kms now since rebuild. Service time including valve clearances using the wire under the valve method , need to order some shims tomorrow . Bike going great

 

Planning to do an Iron Butt SS1600 ride on the old XJ
Ride will be Winter Solstice ride on 21st June ( Winter in southern hemisphere )
I will only go if weather reasonable I dont see it as fun to be riding 1000 miles in pouring rain !
Map of planned route below

https://goo.gl/maps/cii852KusS3WqqRq5

 

Been in lockdown again here in NZ.
Few jobs to do on the old girl .
Slight fuel leak from No3 carb appeared to be float chamber gasket so off with the carbs and new gasket fitted . What a bastard getting the Inlet rubber that have gone hard over the years back on . Ended up boiling them in water before inserting through the air box onto carbs.
I followed the bike when I let my son have a ride a few weeks ago after long downhill sections using the engine as a break getting a puff of smoke from left exhaust . It is using about 1 litre of oil every 1200 km,s . I suspect the valve stem seals have gone hard so another job for the list but for now I can live with a bit of oil consumption.
Fitted some extra spotlights for night riding as the original headlight leaves a bit to be desired .
I am still loving this bike and look forward to plenty of happy KM,s this year

 

Well I haven't been giving my XJ the love . Decided to take it for it Warrant of Fitness inspection last week as havnt used it for a few months and it had expired. Left home early going well then Rev counter dropped to zero and bike died . Coasted to the hard shoulder lucky not much traffic around.
Checked over electrics everything working but no ignition starter turning over and all lights working properly. Fiddled around with all wiring blocks fuses etc but no good.

Phoned my Son in Law and asked him to rescue me with his trailer. Loaded on bike and took it home . Got bike off trailer and though I will just give it another go and off course it started first time !!!!

I cant get the fault to re occur but suspect it could be TCI unit so lucky I have a spare I will pop it under the seat so I can quickly swap if require in future.

Don't you just love intermittent electrical gremlins !!!!

 

Tried another TCI unit and seems to run OK . I am also thinking about new ignition coils as they are nearly 40 years old.
Going to put bike away for the winter so will get her back out around Christmas

 

Time to get out my other XJ900F.
This one is a 1986 model I brought with me from UK. A friend of mine bought it brand new and I took it off him when about 4 years old so owned it about 33 year's.
The frame has rusted out so time for some major work.

 

After a few Months of not doing much I spent the weekend re assembling my XJ900 . Just clean up and refit mainly.
I did find some bad burnt wiring connectors from Alternator so fitted ne terminals .
Hope to give the carbs a clean in the ultrasonic cleaner next week then be ready to fire her up after 4 years

 

With Photos this time .

 

How did you repair the corroded frame or is that a replacement?

 

Hi Franz.

I do have a spare frame but I cut out the rust a couple on mm,s either side of the rusted part and found that the rest of the tube was in very good condition. A friend who is a good welder was able to graft in some new steel and it now looks as good as new . The rust had run along the seam where the tube was manufacture that also happened to line up with the lowest part . It had rusted from inside out so obviously had some water trapped so I have dilled a couple of drain holes in each side now .

 

I had water in my frame. I might drill a drain hole too. How did he join them? Did he fit an insert to bridge one of the joints and weld the end of the other joint?

 

l meant weld the joint that had an insert too .

 

I didn't take any photos of the repair being done . But we cut out the rusted portion then made a piece out of thin plate radiused a curve on it the seem welded then ground it off to a near invisible repair . The frame wasn't badly rusted inside .

 

Carbs cleaned out with New Ultrasonic cleaner today and re installed .

 

Out for a nice ride to Ocean Beach New Zealand .. The old girl going great

 

With the Photo this time

 

Can't get more than 120km from the sea in NZ so it's always a good ride to the coast