Starting a 82' XJ650 maxim Bobber Build

Hey guys, the name is Joe and I recently just bought a 82' xj650.
The plan, as of right now, is to build a bobber with it. Budget is small so it might take some time, but hopefully it works out. So far I've fixed a idle issue by just doing some small maintenance on the carbs and rebuilding them basically. I've also pasti dipped the tank, side covers, and the top of the carbs just to start getting some kind of color scheme going since the bike was 4 colors when i got it.




Day 1
After I dipped the tank and side covers.

I've bought some parts for some front brake maintenance ( new rotor, caliper rebuild kit, new brake pads ). I'll keep posting as the build comes along and let me know what you think or any suggestions to make this build better!

 

Add new brake lines and a master cylinder rebuild kit to your brake maintenance parts list. You can cover the cost by measuring your caliper for runout and finding that it's probalby still in servicable condition; then return the new rotor.
Also thoroughly inspect the rear brake shoes for signs of delamination.
You are wise to be working on the stoppers first.

High-temp rattle-can black will take care of your rusty headers. If the mufflers are in good shape (minimal rust) then I'd just leave them alone since scuffing them well enough for paint to stick is a PITA (plus good chrome is hard to come by).


EDIT: I just noticed that it has non-OEM bars, but still has the OEM master cylinder. You'll want to change that out for a master cylinder that is meant for flatter bars (unless you like to suddenly not have brakes when you need to brake mid-corner because of some asshat pulling out from a driveway).

 

Welcome aboard. Get manual, learn your bike and ask whatever questions you need to. We're here to help.

Gary H.

 

that's not fuel line on your carbs, get some real fuel line. i think your carb tops are on backwards but it doesn't really matter.
get some mirrors and a fender, the fender has kind of a fork brace built into it.

 

Hey Joe,
Welcome to Camp XJ!

If you are going to put pod filters on the bike make sure to gingerly remove the airbox without damaging it.

 

These are awesome responses!!

Dragsta- what kind of jet set up do you have on your bike with those pods? After I put everything back in the bike it would idle just fine, but then after taking it around the block it would just bleed a mixture of oil and fuel out of the crankcase vent hose like a mother. I'm thinking the guy before had the carbs rebuilt by someone who didnt look to see the size main jets the bike needed and they are to big. If this this the case, maybe instead of changing the jets, I can just add the air filters to compensate?

K-Moe- The the rotor is badly worn ( sorry I dont have pictures ) but theres a distinct 1-2 inch groove from where the pads have been rubbing probably for awhile. When I take the caliper off I'll try and salvage as many parts as I can and go from there. Also going to cut the mega-phone mufflers and throw on some pea-shooter shorty mufflers and wrap the pipes. I wanna make the bike functional, but also give it a rat bike look. lol

This is awesome guys! keep the input coming!

 

The mufflers unbolt. Don't cut them: sell them.

 

I've cleaned the carbs. Actually I even took the off a separate time to "re-clean" because I thought the same thing. Tomorrow I'll be taking the carbs off again and checking the sizes of the jets.

I've also got some friends who live in Tampa, zephyr hills. Maybe when I get the bike running I'll take a ride there.

 

I think I have the Xj650 G model, which in that case the mufflers have to be cut in order to keep the middle piece that connects each side of the exhaust together.

 

You have an XJ650J

The crossover pipe is a simple thing to fabricate, and premade Y fittings are fairly cheap as well. Cut the mufflers if you want, but you're throwing good money away (money that can more than cover the costs of fabrication a replacement crossover pipe). The stock mufflers can fetch anywhere between $50 and $100 each if they are in good cosmetic condition. Now if you'd have to have someone do the fabrication work then it might not be economicaly feasible, unless you know a guy that owes you a favor.

 

Well guys, after brain storming with some of my instructors from school (MMI), I took the carbs off again and completely looked everything over. Went to take the needles jets out what do you know, one of them were flipped upside down..
After having mixed emotions of happy I found the problem/ that was really the problem?! I dropped the oil and I really shouldnt even be saying oil because probably 75% of it was fuel.
I fillled it back up with the recommend oil, ran it for about 30 mins, and dropped it again to help flush anything left in there. Filled it again and now im waiting on a new air filter because mine was SOAKED in fuel/oil mixture.

 

Good stuff with the carbs! They're one of the most intimidating parts of the xj. Either that, or the electric system. Ugh! Pre computer computers... lol

 

Your oil/gas soaked filter will stil work once the gas dries out of it. Go ahead and use it while you're waiting for the replacement.

 

I happen to like vacuum-tube computing machines. They keep the whole house warm

 

I tried looking up ways on how to clean the paper filter and pretty gave up and just washed it with soap and water. ALOT of brown liquid and dirt came out of that thing and rinsed it thoroughly. Dried in the sun and in front of fan for about 3 hours and put it back in the bike. Fired it up and took it on a test ride.
Other than it being a little sluggish ( very small amount ) everything felt good.

Filters should be here tomorrow and hopefully I'll be on the road again til I can find a motorcycle jack to get the front end up and change the front brake assy.

 

Next time you can use carb cleaner. If im in a pinch I'll reuse a filter by cleaning it that way (if it's so dirty that it can't be used otherwise). Leaving a light coat of oil on it won't hurt.

For others reading this late on: this is only a way to get by until a new filter can be installed (or a permanant solution if the filter for your wood chipper is like mine, and hasn't beeen available new for 30 years).

 

Quick question guys, what's your thoughts on exhaust "popping"? On Deceleration and sometimes at idle after the bike has been warmed up. What do you think are the best ways of detecting exhaust leaks?

 

Confirm that the idle circuits aren't set too lean first. Exhaust leaks can be found by feeling for pulses with your hand as the bike is running. Careful to not touch the pipes.

 

Stoked!!

 

Oh. You'll want to return that. Leans out the mixture too much. Sorry.

 

Damn - you stole the jelly out of his donut man!

Good to know though cos I was just looking at one!

 

Update:

Sorry for now posting anything new lately (holidays have been keeping me pretty busy).
As of right now, still having trouble with the carbs. Bike is wanting to "pop" still and so i need to mess with the jets a little bit.

Before I mess the carbs some more though, I have decided to change the exhaust and add pods. ( thought to myself I should add the parts I want and then some what calibrate the carbs ).

I will add pictures hopefully within the next couple days of the process.

Quick question before I go, when I'm looking for parts on ebay how much to parts differ from the 1981 xj650 maxim to the 1982 model? I'm finding all kinds of awesome looking parts for a 81 but not so much for a 82.

Thanks and hope you guys had an awesome holiday!

 

You should get a good running baseline in stock condition before making any changes to the intake or exhaust. Doing otherwise means that you are searching for a bullseye in the dark without knowing where you started.

Popping does not necessarily indicate a problem with jetting. There shoudl be no popping with the factory jets.

What do you have the idle mixture screws set at?
What do the plugs look like?
Does the popping occur on acceleration or on deceleration?
Have you checked for vacuum leaks?
Have you checked for exhaust leaks (including holes)?