NEED HELP NEW OWNER OF AN 82 MAXIM XJ550

I recently bought this bike off a friend of mine for dirt cheap because it doesnt run unless it is push started and from what he told me it needs a new starter so today i tried to remove it to check the brushes and for the life of me cannot get it out. i only removed the 3 bolts on the LEFT side holding the starter did i miss a few bolts on the other side or something? any help would be greatly appreciated thanks in advance -Ryan

 

No, there're just the two bolts on the left (the "third" one is just for the sprocket cover) plus the big lead wire on top.

The starter does have an o-ring on its "nose" where it plugs into the case; chances are it's fused itself in there pretty well. You have to pull it straight to the left until it unplugs from the engine case.

You're going to discover you've got a lot more to do to this bike than just fix the starter. I strongly suggest you get a service manual as soon as you can.

 

thanks for the help but i actually got the starter out and tested it and will put it back in tomorrow because it seems as though it works fine and I also printed out a manual for this bike the other day perhaps you could point me in the right direction though because I have a new dilemma the last owner let the bike sit out in the snow for quite sometime with nothing but a tarp over it and the front brake was locked up how do i go about fixing this can i simply change out the old brake fluid?

 

Ummm, no.

If the bike has the original brakes, you're going to need to rebuild the system, and here's why:

The master cylinder and caliper seals had a factory-recommended lifespan of 2 years.

The original brake lines had a factory-recommended lifespan of 4 years. Check the date of manufacture, it's embossed in the lines. Old lines can pop when you least expect it.

You need to rebuild the caliper, master cylinder, and replace the lines and the brake pads. Period. I know it's not what you wanted to hear; it's just the sorry solid truth.

Your life depends on it. Plus, if you don't, you're going to have continual problems with it until you do. Hopefully, one of them won't land you in the hospital. We don't screw around when it comes to brakes.

Before even that, you need to remove the rear wheel and VISUALLY INSPECT the rear brake shoes for signs of delamination: http://xjbikes.com/Forums/viewtopic/t=15874.html This one can kill you, honest.

Sorry, don't mean to pee in your cornflakes, but brakes are more important than how it runs. By the way, based on what we know so far, you've got quite a bit of work to do to get this puppy reliable. Don't hope for "quick fixes" (like just replacing the fluid.) When it comes to a 30-year old bike, there simply aren't any. Just ask somebody who's rebuilt a couple (or more) of them... we've been there, done that.

No shortcuts. (XJBikes Law #1.)

 

Yup, it's one thing to want it to start quickly, and go quickly. BUT you gotta first make sure that you will be able to STOP quickly.

dave f

 

do you think you could provide me with some links to get these rebuild kits for the front caliper and master cylinder?

 

XJ4Ever, link at the top right of the page, or just email Len - info @ xj4ever dot com (no spaces)

He'll have everything you need.

 

You might want to print this out and save it.

The factory fiche screwed up the parts diagram, and even the factory manuals don't label every part.

This is a 550 Seca caliper; yours is simply a "mirror image" of this one. I'd "mirror" the pic for you, but then it would be kinda hard to read the text.

 

I have the same bike, I've been working on it for a while now and it is really starting to get dialed in nicely with everything working, and lots of upgrades and safety items addressed.

While you have your starter out you should closely inspect it. I just pulled mine at 9800 miles and everything was fine internally except the grease was solidified and virtually dried up. Not good.

I cleaned and regreased the planetary gears and the end cap bearing on the brush end of the starter. Now I know its condition, installed it with a new o-ring, and its set to use for hopefully a long time. There is a special grease that is used for that and several other area's on the bike, you can get it from Chacal at XJ4Ever.com at the top of this page. Good stuff
Good luck with your bike and enjoy!

 

I am actually in the midst of complete front brake overhaul/replacement right now on my 550. New EBC brakes which are far superior to the 30 year old brake pads, new stainless steel brakelines (much better), wheel cylinder and master cylinder rebuild kits, and any corroded hardware I bump into.
I already went with new EBC brakes in back, just because they are a better brake.
I ride hard and should a situation develop in front of me I need the bike to respond with control and precision!!!

 

Make sure you clean out the old dried up fluid and gunk from the piston and caliper bore,I used a dremel with a small green scotchbrite pad attachment,It worked great and saved alot of time...