Getting an XJ550 Running Again

Probably not as likely - but I got faked out once by a sticky start switch. The start switch would stick, then after the bike was running and the start switch was still stuck, the oil light would be on - in other words, bike running + start switch pressed = oil light on. I had to clean and lube the start switch to work properly, then no more false oil light.

 

Because that’s the direction you turn it

 

It will turn but you have to turn much slower and carefully

 

CCW the way the wheel and motor turns when running and rolling.

clockwise you are fighting against the cam chain tensioner

 

SUCCESS!!! I'm up and running. Cruising around the neighborhood.

Big thank you goes to each of you @XJ550H, @hogfiddles, @Dan Gardner, @dkavanagh, @Timbox, @Ryengoth, @Simmy, @Hillsy!

 

Now that I've got gas in the tank, the leak in the petcock has been discovered. I've got parts in the mail to rebuild it.

When I got back from my first few rides, I kept on noticing that there is a a wetspot on the floor under the left fork. While I was on it at a stop sign I noticed bubbling at the seal. I'm seeing others talk about replacing seals. I'm still investigating the minimal work needed to stop the leak. Any "go to" threads?

 

of course

Rebuilding the Yamaha Vacuum Fuel Valve w/pics

 

Thanks for sharing that link. Looking to use that tonight when the parts get in.

Any good links or pointers on the fork?

 

Petcock rebuilt. We'll see if the leak stops.

Is there a troubleshooting guide for leaking forks?

 

Step 1 - rebuild them
Step 2 - go ride

 

Heh, I was hesitant to say "if they leak, rebuild them", but you basically did it for me.

 

Removed one of the my two additional fuel mentioned here and now it's idling all over the board. I feel like I'm starting over with idling. Are there any guides on getting the idle right?

 

Got the idle down. Took a while and some singed fingers but it idles smoothly now. I'm needing to tweak the choke and the idler.

 

The master cylinder for the brake is damaged. It works. There some mushiness in the brakes but it works. The levers on both sides are broken short so I'm in the market for new levers. Between the two, I'm looking for a new master cylinder and lever. Having trouble matching what I'm seeing online to what I have. I think the cylinder was replaced by a previous owner. Does anybody have a good picture of master brake cylinder for a XJ550?

 

Getting the list of stuff out of my head:

• Lube the Speedo and Tach
• Replace front forks seals
• Straighten the rear brake lever
• Replace levers on handlebars
• Replace master cylinder
• Figure out why the headlight does not work
• Reduce idle speed when hot down from 3k

 

This one is good for pictures, not sure I'd buy it though... missing the cover and diaphram (but you'd probably buy a new one of those and a rebuild kit for the plunger anyway).
https://www.ebay.com/itm/2839793931...rentrq:b096921917b0ad33096751a6fffb52e2|iid:1

 

Asking before I burn it out.... Is the headlight a 12v headlight? I'm thinking about testing the headlight by hooking it up to the battery directly. Just to eliminate the relay as a possible source.

 

Installing the clutch lever on the crankcase. The manual says to "make sure that the punch mark on the level should align with the mark on the crankcase cover when pushing the level towards the front by hand". What's the proper alignment of the clutch lever on the spline? do you just leave the spline with no tension and put the lever on where it aligns with the mark?

 

Just did a compression test on the cylinders.

Current state of the bike:

• Airbox boots are removed off the carbs
• Gas tank is over to the side with a fuel line running over
• Some fuel in the line
• Up on the center stand
• Console (speedo and tach) is removed
• Headlight is removed

Here's what I did:

• Fully charged the battery
• Cold
• For each spark plug
  • Pulled a spark plug
  • Installed the compression tester gauge (link)
  • Cranked until the reading stopped moving
  • Write down number
    
  • Removed the compression tester gauge
  • Let cool

With that procedure, I got these numbers

1. 150 PSI
2. 155 PSI
3. 125 PSI
4. 145 PSI

Known limitations in the procedure I used:

• TCI was still connected
• 3 plugs were still screwed in each test
• Throttle was closed
• Engine is cold
• An adapter was used for the compression tester
• No oil was infused in the cylinders and the test repeated

According to the Information Overload I should be around....

XJ550 engines:
Minimum: 100 psi
Standard: 121 psi
Maximum: 135 psi
Max. variance between lowest and highest: 14 psi​

Questions for all:

What are the symptoms that would align to over compression?

 

In other news, I have:

• I've tried vacuum syncing the carbs
  • mixed results on this
• Rebuilt the console and lubed the speedo & tach
• Removed the headlight so I can troubleshoot why it's not working.
  • Initial test with a Multimeter shows that no power is getting to the relay
• It's having trouble starting now

 

Oh, when I was trying to get the bike started to test the tach howing, I noticed that there was smoke coming out of cylinder #1 (far left side). I could not tell where exactly it was coming from but it was the front side of the block.

 

Likely oil burning off

 

I had the bike idling on the kick stand in the drive way without the airbox boots on. After all the recent work that I've done. I wanted to keep a close eye on it for a few minutes. Rev it here and there. When I noticed that a drop of gas from the heat shield. Bending down, I noticed drops on the bottom of carbs 4 and 3 (4 and 3 are the left hand side right?). Tweaking the choke as needed and reving here and there. Next thing I know the closest carb, #4 right?, just starts coughing up gas. Not a little dribble but a spew of gas.

I'm thinking that the floats are off OR the needles are not sealing. Either way the carbs have to come off. What are your thoughts?

Is there a document of tests that we can do on the carbs to make sure everything is good and sealing well before we but them on the bike? Like filling the bowels and making sure they don't overfill or something?

 

Yes, if you do the "wet set" procedure, that tests them off the bike with gas in the float bowls. You'll be verifying fuel level in the bowl to tweak the float levels. This will also test to be sure the float valves seal.
I couldn't find a link (forum search says "wet set" is not something I can search on... ).

• The procedure is to set up the carbs, level on the bench. I used some deck screws into a board to support all 4 corners of the rack.
• Next, supply fuel via an elevated tank of some sort. This should allow the float bowls to fill.
• If nothing is leaking at this point, move on to checking float level.
• Connect a small tube to the fitting on the bottom edge of the bowl near the set screw. There's a drawing somewhere that shows this (I'll try to find it). By holding that tube up along side the carb and opening that set screw, the fuel will rise in the tube to match the level in the bowl, so you can see if it's within spec.
• For any that are out of spec, you'll need to drain the bowls and remove the problem one. There's a little tang on the float where the float valve needle attaches. By *slightly* tweaking the tang, you can adjust the float level, and thereby the fuel level in the bowl
• Repeat the measurement till things are all in spec.

Here's a helpful PDF another forum member put together. (I probably should have led with this!) http://www.xj4ever.com/setting fuel levels.pdf

 

Going upstream, literally.

Got some Evaporust in the tank to eat up the rust and then will be using Red Kote to seal it up.

The fuel level sensor. Got any advise on remaking that gasket? I'm thinking a layer of silicon sealant. Thoughts?

I busted one of the bolts on the fuel level sensor. Dumb but potentially easy question. Do the bolt whispers of Ace have these bolts?

 

xj4ever sells the gasket and bolts get the correct parts thats not a place you want fuel leaking from

 

The Red Kote is curing now. I'm noticing small bubbles formed. SHould I be concerned?