Pumba the XJ750 project

Finally worked out some better coil mountings.

1 + 4 are on top of the rocker cover;


Mount plates still need to have the corners rounded;


2 + 3 will mount up under the tank in the original position;


Somewhere about there;


Just waiting on the connector plugs and its fit up and test time.



No more Original coils or TCI unit

 

What front end/wheels did you use and how much effort to graft them onto the 750 Seca steering head/final drive?

 

The wheels, forks and diff are all from a Australian delivery XJ750P police special. The fork part numbers actually match a XJ750D (EFI Japan only market)

 

OK - thanks. I was hoping that 650 turbo-like wheel/non-leading axle front end combo would be available in USA-spec'ed parts too.

 

GM LS1 coils fit and clear the tank





Once the connectors turn up (almost 3 weeks wait so far), its time to fire up the Microsquirt and finish programming.

(And round off the mounts and make spacers instead of stacked washers)

 

825 big bore engine is ready for final clean up and assembly.

New bearings are in spec;



So now its clean and paint.



Then assembly

 

WOW.

jus went through the whole build - excellent work man, your cnc work is great as well, as the knowledge to make nothing into something is just impressive.

I will deff be watching this from now on, thanks for sharing with great pictures and explanations!

Chris

 

Update;
Behind schedule on everything in life including Pumba.

But committed myself to a farride tomorrow that will be the old engines swan song.

Minimum of 1,000klms tomorrow (a short version of the iron butt ride the USA does).

Plugs changed, gel seat cover on and fingers crossed.

 

Hope it all goes well and you enjoy th ride, my longest day was Eucla to Kalgoorlie on a CB750. I was heading for my girlfriend at th time so had a bit of extra impetus. I was looking at th farride site just before checking on here...

 

Overdue update.

Bottom end is together and cases tensioned up.

Final parts list done and sent to xj4Ever (len).

I have given notice at my job of 7 years and will soon be an Apprentice trainer of Mechanics, so a lot is happening.

Pumba is about to get a big injection of funds (I had 8 weeks holidays owing).

No pics of the engine assembly due to my Pentax DSLR being stolen out of my car.

But for those following Pumbas build, the engine;

Low KLM police engine.
Full gasket set.
new primary chain and guide
new timing chain and front and rear guides
6 new main bearings (all in spec now)
Wiseco 820cc forged piston kit, bored and honed to suit.
light head surface and light valve lap in.
new starter clutch (rollers/springs and whatever)
new oil pump chain
new oil level window
new clutch pivot shaft bearings and seal
Spin on filter set up
new clutch pressure plate pushrod/bearing/washer
Numerous dowels and seals

I WILL be doing a base dyno run on the old engine, and WILL be doing another run on the new engine after a decent run in.

So May is the month for the new engine, and panniers for long distance running.

Pumba, on the road for 18 months and 10,000 klms, Zero breakdowns.

Now we get serious about some distance.

EFI is still happening, and may be set up on my spare frame with the old engine first. (if the old engine survives the dyno run)

 

After 2 far rides (1,000klm in 24 hours) Pumba ended up at a Bikini wash in aid of the state spinal research unit (MAD or Make A Difference).





Awesome day and the girls had fun. Pumba was probably the oldest bike there.

Thinking about it, this would have been Pumbas first encounter with a female.

 

At the end of the month Pumba will have a rest from the road, and get new paint and the new engine fitted.

Proof of progress! (and new camera)

 

Nice! Good job on the paint, and the pics are excellent.

 

Nice hanging and priming (I guess). What color are you going for?

 

Finally had a chance to run up the old engine so I have a base to compare the 820 engine and the following mods.



Bog standard XJ750, Mac 4 into 1 exhaust, fresh plugs, clean air filter. (engine tired and uses oil)

 

not too bad for a tired engine bloke ?

what are you aiming for with the big bore kit?

How will the bottom end react to more power?

are you doing anything to the bottom end to beef it up?

Cheers

OZ

 

Bottom end should be fine, as it is pretty much the same as a 900 to start with. And power probably wont exceed 20% over stock. I do however expect more midrange and less fuel usage.

 

Current things happening:

A half done paint job (only the base color so far)

 

I am more than happy with the base color, fingers crossed the second contrasting color looks as good.




And roo spotters:


By the end of winter we should be looking great!

 

Which paint did you use on the hanging engine above?