Hello, please help with information on 82 XJ650

Hello, as you can see first post ! My father bought this 82 XJ650 Maxim in Franklin PA around the late 1980's and I have owned it from 1999. 18K miles, always garage kept, very clean and after only putting on 200+/- miles yearly, over the last 9 years it started dumping fuel into the airbox. Pulled the (never off before) carbs and only the left one had some blackish mystery crap (fuel line?) in the bowl. Now, to get a carb rebuild kit, thoughts ? I found it strange that the adjustment screws were set so different as follows Left 23/4, 35/8, 41/4 and Right carb 13/4 turns out ? The starter button keeps popping out any rebuild parts ? They key is getting weak how/where to get another made ? When pushing the bike around the front pads are dragging hard for half the wheel turn and the other half free wheels, I've rebuilt the master cylinder and the caliber so, could it be a warped rotor and could it be turned ? Thank you for any help suggestions Chuck S.

 

If the mixture screws were adjusted, then carbs have been off before. From the factory they came with blank plugs over the mixture screws.

Dumping fuel is from non-sealing float needles. There are certainly plenty of carb kits available. Not sure if any are particularly bad. JetsRUs has a good assortment of OEM and aftermarket carb parts, and XJ4Ever has basically everything for these bikes.

 

Sometimes cleaning the float valve seat with a golf tee helps clean out debris that prevents the needle from seating. I'd concentrate on the lower end of the carbs, Seat, float valve and bowl passages.

 

In the UK, Yambits do a starter switch button kit, Yambits : for Yamaha bikes

The horn button is the same and I've had to replace it on my 1980 XJ650 4K0.

 

Thank you for all the replies, please keep the suggestions coming.

 

Check the oil too in case there is fuel in it. Faulty petcocks can cause this. Check oil level on window in clutch cover. The original brake lines could have deteriorated inside causing binding brakes. You should put new ones on.

 

"Faulty petcocks can cause this"
Interesting, maybe all my work is for not, it literally dumped fuel into the airbox...

 

The engine cover below your alternator has a breather pipe which goes to the air box. Check that it should only take crankcase gasses to the air box. More likely to force fuel into the air box during engine cranking. Take the spark plugs out and the left timing cover off and rotate crankshaft anticlockwise with a 19mm spanner. If fuel is in the cylinders it will come out of spark plug holes. Better doing it outside.

 

Yes it operates from engine vacuum there should be two pipes one for vacuum and one for fuel on the original petcock. Fuel should flow when the engine is not running only when the petcock is set to prime.

 

Would it be better to rebuild the Petcock or replace it completely ?

 

Rebuild it Len has the kit you need contact him on info@xj4ever.com