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Trokel's XJ900 thread - and other bike stuff

Discussion in 'Hangout Lounge' started by trokel, Aug 31, 2012.

  1. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Have been really busy with my project boat but that doesn't mean the bike is getting left out so I thought it was time to update what has been going on.

    As far as the forks are concerned - This is where I got to.
    I decided that if I was going to install the 85 forks I would need to polish them up so that they looked as good as the current ones otherwise I wouldn't be happy with them. As it turns out, it wasn't as hard as I thought.

    Here they are showing one before and after it was finished
    [​IMG]


    Then I popped up the dust seal on the leaking fork leg on the bike and cleaned up the excess oil so i could check it out. I pumped them up and down really hard to see if i could get it to leak but it was fine so I decided to keep using it to see how it went.
    In the mean time I ordered the necessary parts from Len to rebuild 85' forks so that I could have them on standby.

    Shortly after all this I did a 400km loop through the mountains and gave the bike a really good work out. To my surprise it still didn't leak :?
    Then a few weeks later on a short ride around town it blew oil out everywhere again so I'm not really sure what is going on. During this time the parts from Len arrived and now the 85' forks are all polished and re-assembled waiting to be fitted. After that I plan to play around with the jetting some more so that I can get it ready for the Honda Broadford Bike Bonanza at Easter time where i intend to give it a run around the race track. :wink:

    So that is how the No.1 XJ900 is going. I say No.1 because as of yesterday i now own another one which from here on in will be referred to as No. 2. It is an 85 Model and it's future is yet to be determined. However If I do decide to restore it at least I know that I will can get all the parts i need in one place. Thanks again to XJ4ever.



    XJ900 No.2
    [​IMG]
     
  2. murray

    murray Member

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    Re: Trokel's XJ900 thread - a work in progress

    The '84 xj900 that I had 3 years ago came with the non anti-dive forks already fitted .The PO said that they were a big improvement over the original. With the current xj900 project ,I went to the wreckers and bought a set off a xj900N, replaced the top slider shells in the fork leg, (common size at any bike suspension specialist ), replaced the seals and dust caps and used one grade heavier fork oil, much betterer.

    cheers , Murray
     
  3. quebecois59

    quebecois59 Well-Known Member

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    Re: Trokel's XJ900 thread - a work in progress

    Very nice bike!

    I'm in the process of designing my own backrest for my '83 Seca 900 and I'm not quite sure if I'd like to make my own rack at the same time. It would help me a lot if you could send me some close pictures of your rack, paying special attention to the mouting points on the frame.
     
  4. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Hope this helps.

    The brackets are a bit rough as they were knocked up in a hurry as a temporary thing but they worked out to be very strong and are hidden by the side covers so i haven't bothered to change them.

    [​IMG]

    [​IMG]


    [quote = Murray]The '84 xj900 that I had 3 years ago came with the non anti-dive forks already fitted .The PO said that they were a big improvement over the original[/quote]

    I am hoping that will be the case. On the last ride i did through the mountains I bottomed out the front end a number of times when coming into the corners under brakes.
     
  5. quebecois59

    quebecois59 Well-Known Member

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    Re: Trokel's XJ900 thread - a work in progress

    This is an accurate picture of the side mount, thanks a lot!

    Now, I suppose there are two other mounting points on the back, close to the license plate. Could you please take picture of them also, and finally a general view from behind the bike?
     
  6. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    The other mounting point is also shown in both pictures.
    If you look closely on the left hand side of the top picture you will see a silver bracket that comes down from behind the duck tail and connects to the tubing of the rack. Then in the far left of the 2nd picture you can see the top of the bracket where it bolts to an existing mount that was on the frame. These are the only 2 mounting points on each side
     
  7. quebecois59

    quebecois59 Well-Known Member

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    Re: Trokel's XJ900 thread - a work in progress

    Oops, didn't noticed at first sight ! I would have thought the rack would be bolted to the tail section in the back in any manner, but I was wrong.

    I would appreciate a general view of the rack from behind the bike, if possible.

    Thanks again.
     
  8. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Sorry - have been a bit busy so I haven't got around to taking anther photo yet.



    My young bloke turned 8 the other day which means he is now old enough to be a pillion and seeing he has shown some interest in the bike i decided to get him a helmet and take him for a spin to see how he likes it. As it turns out he seems to love it and he also makes a really good passenger So it looks like I have another reason to go for a ride. :D Just need to get him some better riding gear.

    However - One thing i noticed while taking him for a ride was when I gassed bike up from a slow rolling start the clutch seemed to slip a bit. This is the second time that I have noticed it but it doesn't seem to do it all the time. Currently I use Castrol 4T motor bike oil and was wondering if my clutch was on it's way out or maybe changing to a different oil might help. Thoughts anyone



    [​IMG]
     
  9. gunnabuild1

    gunnabuild1 Member

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    Re: Trokel's XJ900 thread - a work in progress

    I found with mine clutch slip shows up when it hit's 6 or 7k revs just as the bike really wants to pick up and fly the clutch gets overwhelmed and slips.
    I assume you've checked your cable adjustment ?.
     
  10. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Hope this helps

    [​IMG]



    I haven't checked the manual to see what the recommended setting is but the lever does have a reasonable amount of free play and the cable runs nice and smooth so that shouldn't be a problem.
     
  11. quebecois59

    quebecois59 Well-Known Member

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    Re: Trokel's XJ900 thread - a work in progress

    Thanks a lot, Trokel!
     
  12. mtnbikecrazy55

    mtnbikecrazy55 Active Member

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  13. wizard

    wizard Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    How did I miss this thread? that tank & side panel mods are a class act. What are you going to with the latest 900, I found all you could do was put it back pretty much as it was.
     
  14. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Thanks for the links
    I have some time off in March and plan to spend a bit of time working on the bike to get it ready for the Bike Bonanza at Easter. The main thing I was planning to do was fine tune the jetting as it is a bit rich at the moment. Looks like I might add the clutch to the list as well.
     
  15. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    If you are like me you are probably too busy working on projects and don't have enough time to keep track of what is going on here. Which is why I sometimes ask specific questions in other areas of the forum in the hope that they will attract more attention.
    However I still like to keep it all tied together so that people can get the full picture so here is a link to one of those threads

    http://xjbikes.com/Forums/viewtopic/p=3 ... tml#363239

    As for what I am going to do with XJ2 - Not Sure yet - It's Early days
    But whatever I do I will continue to document it on here for anyone who is interested.
     
  16. mtnbikecrazy55

    mtnbikecrazy55 Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    You'll be glad you did for sure-

    It's actually a really easy job - start by putting the new friction plates in oil to soak, then just pop the clutch cover, scrape the old gasket material off (the hardest/most time consuming part of the whole process imho) take out the plates, scrub the plain plates with a scotchbrite pad, then re assemble with the new friction plates and springs. Then, i just used a bead of ultra black RTV sealant when i re-installed the clutch cover.

    New clutch spring bolts are also recommended, and available for just a dollar or so at your local yamaha dealer.


    Fitz did a great write-up here:

    http://xjbikes.com/Forums/viewtopic/t=29541.html

    I also installed a new clutch cable at the same time, and here's Rick's cable adjustment procedure:

    http://xjbikes.com/Forums/viewtopic/t=2 ... cable.html
     
  17. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Have found a bit of spare time recently to work on the bikes so here's how things are going.

    I finished rebuilding my spare 85' forks and have fitted them into the 83' bike (XJ900 no.1). They fitted up without any problems and look good but as I have only done a few short rides I can't really comment on whether they are an improvement or not.

    [​IMG]

    I have also started working on XJ900 no.2
    The bloke I bought it from didn't know much about it's history, all he could tell me was that it had been sitting for a couple of years. He said when he tried to start it, it fired up OK but fuel was pouring out from around the carbies so he shut it off and left it at that.
    So I decided the best plan of attack was to pull the carbies and see what I could find and here's how they looked.

    [​IMG]

    Once I opened them up it was instantly apparent what the problem was. All the floats were stuck solid with the needles in the open position. This would explain why the oil level in the sump was so high, fuel had obviously leaked into the sump a well.

    This time rather than trying to punch the float pins out like I did on the other bike I used some multi grips and a small piece of tube to press the pin out enough that I could grab it with some small side cutters and then lever them out. I found that this worked really well.

    [​IMG]

    [​IMG]

    Here's an idea of how dirty they were. Look at the blocked emulsion tubes.

    [​IMG]

    But with a bit of work they cleaned up OK. Here I have cleaned the carb bodies and am about to start on the jets etc.

    [​IMG]
     
  18. trokel

    trokel Member

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    Progress Update

    Here's what I have been up to lately.

    After cleaning the Carbies on the 85' XJ900(XJ No.2) I stuck them back in, changed the oil and tried starting it and too my surprise it fired up and idled quite well. I was also very surprised to see that it didn't blow any great clouds of smoke. It did however lack throttle response and further investigation revealed that it wasn't firing on all 4 so i metered out the ignition coils and found it had 2 faulty plug caps and also had a mixture of spark plugs some of which were the wrong type. So I replaced the plugs and caps and tried t again and it ran very well so it looks like I might start fixing it up rather than striping it for parts. :D
    I did however have a problem with the standard fuse box and although I had read here on the forum that they could be a problem it was only after working on this one that I saw how bad they are so I decided it was time to replace the one on my 83' as it is getting a lot of use at the moment and I need it to be reliable.

    Here's how it turned out

    [​IMG]

    [​IMG]
     
  19. 750E-II_29Rbloke

    750E-II_29Rbloke Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Nice, was that fourth fuse area melted from bad connections heating up in the old fuse block or is that just the crap left by powdered connectors? Looks like it got a bit warm :?
     
  20. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Also 2 weekends ago I finally got to test out the new forks in the 83' when I took the missus away for a night with some other couples from the Griffith Classic club. It was a great ride through the mountains and to top it off we spent the night up at Jindabyne near Thredbo over looking the lake from the balcony of our unit.

    [​IMG]


    Here are the bikes at Geehi Hut
    [​IMG]

    And a couple more photo's
    [​IMG]

    [​IMG]

    Thankfully the rebuilt 85' forks performed quite well but with the 2 of us and a bit of gear on the bike I found the rear shocks weren't quite up to the task so that might be the next thing to upgrade.

    But that will have to wait as tomorrow i am off to the Honda Broadford Bike Bonanza :D
    For those that want to know more here are a few links to some sites that will explain what it is all about.

    The Event -
    http://www.ma.org.au/index.php?id=hbbb

    The Venue -
    http://www.motorcyclingvic.com.au/index.php?id=363

    This will be my first camping trip on the XJ and i will also be running it on the track so i should have some great photo's and stories when i return
     
  21. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    It was actually the remains of a dodgy repair that was done by one of the previous owners.
     
  22. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Got back from Broadford this afternoon and had a fantastic time. Ran the bike on the track for all 4 sessions yesterday but by the last one my clutch was starting to slip quite badly so i decided not to run it today especially considering that I still had to ride it home. Other than that it ran brilliantly. Looks like i might finally have the carbies set about right now I just have to get the clutch sorted.

    Here are some pics

    [​IMG]


    [​IMG]

    [​IMG]

    [​IMG]


    And aside from riding on the track there was heaps of other stuff to see as well

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    It was so great to be able to enjoy the bike the way that nature intended without worrying about vehicle traffic,police and unpredictable road conditions.
    I rode it like I stole it and loved every minute. :D

    Hopefully in the near future i will be able to post up some video footage from the event as well.
     
  23. adrian1

    adrian1 Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Great work. Thanks for sharing. Xj looks goodin all black. Also is a good palette for extra chrome! Looks like a mackintosh suzuki at broadford? Always loved those things!
     
  24. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Pretty much you name it, it was there.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
  25. trokel

    trokel Member

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    Broadford Video

    Here is a link to some video footage from my track run at Broadford.

    http://youtu.be/7UIDqNWeBu4

    The camera that I was using belonged to a mate of mine and he has put this clip together so thanks very much to him for his work. :D
    The straight sections of the track have been edited out to reduce the running time as we all know anyone can ride fast in a straight line but unfortunately as a result you don't get to see how well the bike performed compared to the other ones in the group. In my opinion the bike handled very well in the corners and held it's own against the smaller/lighter bikes but then when it hit the straight it blew most things in the group away at least until the clutch started to give out. There is no doubt that I could have pushed it even harder in the corners but I tend to be a fairly cautious rider and after all this was not a race. We were just out there to have fun.

    Also at the end of the video it says 85' XJ900 but it was actually my 83'. However it now runs an 85' motor and forks as well as the XJR1200 tank so it does suffer from an identity crisis. :lol:
     
  26. 750E-II_29Rbloke

    750E-II_29Rbloke Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Now there's a use for a z13... wow :lol: bet it's reassuringly stable to ride too with that wheelbase!

     
  27. quebecois59

    quebecois59 Well-Known Member

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    Re: Trokel's XJ900 thread - a work in progress

    Made me think of these ultra-long wedding limousines! LOL!
     
  28. quebecois59

    quebecois59 Well-Known Member

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    Re: Broadford Video

    Nice video! Found myself leaning on my office chair while you entered sharp turns!
     
  29. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Thought it was time I added a bit more to this.
    I have been extremely busy since my last post as I have added 4 more bikes to the shed but they are not XJ's.
    I bought a Yamaha PW80 for the young bloke and a CT110 Postie to follow him around on then i ended up buying 2 Yamaha AG200's cheap that I am in the process of getting going so that I can ride one of them and the Missus can ride the Postie when we take the young bloke out riding.

    Here's a few pic's
    [​IMG]

    [​IMG]

    Also after my clutch problems with XJ no.1 at Broadford I purchased some new clutch plates and heavier springs when I got back and finally got around to installing them recently which seems to have fixed the problem. One interesting thing that I noticed was that there didn't seem to be anything wrong with the old clutch plates, they still measured as if they were new and the springs were within spec as well but the new springs are definitely heavier and that seems to make a big difference.


    Here are a couple more photo's of me and the bike on the track at Broadford

    [​IMG]

    [​IMG]

    [​IMG]



    Will be heading down to Winton on the XJ on Sunday to watch the Historic races so should have some interesting photo's to show from there when I get back.
     
  30. adrian1

    adrian1 Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Good stuff! Check out the width of the motor on the old Honda or whatever it is behind you! :lol: Or is it a Beemer? :oops: Good weather this weekend, cool start though. Watch those Vic cops, they'll nail you for just a few kms over te limit. Gundagai and Albury are also hot spots!
     
  31. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    The cool start didn't worry me but the thick fog was crap and took ages to clear. But it did turn out the be a lovely sunny day in the end and the Autumn scenery was spectacular. :D

    [​IMG]

    [​IMG]
     
  32. mtnbikecrazy55

    mtnbikecrazy55 Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Odds are the old friction plates were hardened from sitting half out of oil for so long.

    Just wait till you break the clutch in even more, so much nicer than slippin' city
     
  33. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Possibly
    When i bought this motor the oil had been drained from it and who knows how long it had been sitting like that for.


    This shows the difference between the old and new springs
    [​IMG]
     
  34. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Hi all been a while since I was on here as i have been too busy working on bikes.
    Here is a pic of the current collection - 2 x 82 model Yamaha XT200's, 2 x AG200's, 2 X XJ900s and a 1980 XT250, a PW80, Kawasaki KLR650 and an 87 model Honda CT110 (postie bike)
    [​IMG]

    Now I know that I created this thread for my XJ900s but seeing as it is in the general lounge i figure i will show you a bit of what I have been up to lately. MAYBE I SHOULD CHANGE THE THREAD TITLE to "What's Trokel been up to lately" BUT I AM NOT SURE IF THAT IS POSSIBLE so in the mean time -
    Below is an edited extract of what I posted in ADV about the 2 XT200's that I purchased for $100.


    The 2 XT200s have now merged into one.
    The one with the red tank next to the postie has been dismantled. Generally it was in better nick than the other one but it had a damaged crankcase and leaked oil. The other one was in very poor condition and missing numerous bits and pieces but I decided to see if I could get it running as it I figured that it would be easier than swapping the crankcases. So after repairing the CDI, cleaning the carby, replacing the broken kick starter shaft, turning up a new spigot for the rear brake lever and welding it into the frame because the original one had snapped off and was missing, I put some petrol in it and got it to start but the engine rattled like mad. So I checked the valve clearances which were fine and then after some research discovered that the cam chain tentioner on these is adjusted manually and was way too loose. Once i adjusted that the motor sounded pretty good but then i discovered that the clutch didn't work. The actuating lever on the motor seemed to be jammed so I dismantled the clutch but couldn't find any obvious reason for it. It just didn't make sense. So I pulled the other damaged motor apart to compare and from that I discovered that the pushrod and ball bearing that runs internally from one side of the motor to the other to actuate the clutch had been installed incorrectly by a previous owner and was now damaged. So I replaced that this morning and after tidying up the wiring and fixing the brakes I was riding it around the backyard this afternoon

    I was determined to get one going as i reckoned it would make a great bike to use with the kids. Initially I got both of the engines running so then it was a matter of working out which one of them had the least amount of problems and then concentrating on it.
    Now that I have succeeded I am really looking forward to getting out riding on it next week with the kids.


    Here are some pics.

    For those of you who haven't seen them before this it what it first looked like.
    [​IMG]

    And here is a shot of the 2 of them while I was still trying to work out which one to use and which one to scrap.
    [​IMG]


    When I realized that the frame was broken I thought, Oh well I have another frame but when i removed the brake lever from it I found it was broken as well. The spigot on the right is from the other frame which I still plan to repair and repaint in the future. The one on the left is what I turned up on the lathe and welded into this frame.
    [​IMG]


    Here's a pic of the spare motor (the one with the damaged crankcase) This was when I was trying to sort out the clutch issue for the other motor. see the pushrod and small ball bearing in the bottom of the picture? That is what had been installed back to front in the other motor and was stopping the clutch from working.
    [​IMG]


    Yesterday i fitted some pillion pegs that I pinched of the 250 and thought that I better fit some kind of chain guard for safety so knocked this up out of aluminum in my homemade sheet metal bender.
    [​IMG]

    As you can see in the picture above the bike is still in need of a good paint job. I wasn't going to worry about that at the moment but when i got up this morning and found that it was another cold and miserable day (note- I am on holidays at the moment and should be doing concreting etc.in the yard) I decided to fire up the heater in the shed and start on a bit of cosmetic work.
    The heater - Two speed fan forced and made from an old gas Cylinder which I got from Aussie junk out at the tip when it still existed.
    [​IMG]

    This is what i call the fitted sheet paint job
    [​IMG]

    And here is the final result. Well at least the result at the end of today. Can't really say that it is final result as I have more cosmetic work to do and other plans for it in the future. Maybe even rego one day. Also it is still missing the side covers as neither of the bikes had them but at the moment I can't justify paying what the wreckers are asking for them. Also I have some XJ1200 side covers that i got cheap so i might adapt them to it yet for something different.
    [​IMG]

    [​IMG]

    Next week with a bit of luck I will have some pics of it in action

    As for the XJ's, number one is still going strong and is getting used regularly, even took my young bloke away on it for an overnight ride last weekend and as for XJ900 number 2 i am in the progress of researching sidecars with the intention of maybe fitting one to it. Will keep you posted on how that goes.
     
  35. mtnbikecrazy55

    mtnbikecrazy55 Active Member

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    Re: Trokel's XJ900 thread - a work in progress

    Wow! Nice job!

    To edit the title just go back to the first page and edit the first post :)
     
  36. MarkV

    MarkV Member

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    Re: Trokel's XJ900 thread - a work in progress

    great job.
     
  37. RobbieRobot

    RobbieRobot Member

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    Re: Trokel's XJ900 thread - a work in progress

    You've certainly been busy. Have fun.
     
  38. RobbieRobot

    RobbieRobot Member

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    Re: Trokel's XJ900 thread - a work in progress

    You've certainly been busy. Have fun.
     
  39. gunnabuild1

    gunnabuild1 Member

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    Re: Trokel's XJ900 thread - a work in progress

    That XT looks pretty damn good!
     
  40. trokel

    trokel Member

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    Re: Trokel's XJ900 thread - a work in progress

    Done - Thanks for the tip

    And thanks everyone for your comments. Currently the work i have done on the XT200 is to make it usable and look OK at minimal cost and I am really happy with the result. It was the same for the AG 200 which I bought for $50 and was in terrible condition.
    As can be seen here.
    [​IMG]

    Here is how it looks now

    [​IMG]

    Once again it was all done as cheaply as possible. Here is a list of some of the more major repairs that were done to it. (note - I can provide photo's for more detail of these repairs at request if anyone is interested)

    *One of the main problems with the 2xAG's and XT200's was the CDI's were faulty and seeing as I didn't want to fork out $350each for a new one i worked out how to repair the old ones.
    *The original muffler was completely stuffed so I made a new one from an old fire extinguisher.
    *The seat was stuffed so I repaired the foam and made a new seat cover from some left over vinyl I had laying around
    *Then there was all the other usual things to fix like cables, brakes, wheel bearings and strip/clean the carby etc.

    One might ask why go to so much trouble with seemingly worthless old bikes? But in all honesty I have really enjoyed the challenge of getting them going, spent very little in the process and have just gotten back from a few days away with the family where we had a great time tearing around on them which was when the above photo was taken.

    There is more photo's to come of our recent trip but first i have to get ready for a few days away on the KLR where I will be heading to the sidecar rally to get ideas for another project.
     
  41. trokel

    trokel Member

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    Hi everyone hope you all had a MERRY XMAS. I can't believe how quick this year has gone and I am also amazed to see that I haven't posted in this thread since September.

    So here is a taste of what i have been up to.

    At the start of November I took the missus away for 2 nights on the XJ for our anniversary and had a great time even though the bike broke down.
    Sorry but I have just run out of time as I need to go and sort out the kids so I will have to continue this story later

    However in the meantime here is a photo from the trip

    [​IMG]
     
  42. adrian1

    adrian1 Active Member

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    Broke down? Dont leave us hanging :(
     
  43. trokel

    trokel Member

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    Sorry to leave you hanging but the kids were being difficult.

    For our anniversary we were booked into a cabin in Healesville which makes for a great ride through the mountains. We went through Whitfield and over to Mansfield then decided to go the back way via Jamieson to Eildon which was still dirt last time I went that way but has now been sealed and is quite a long stretch of twisty bitumen. It was along here that the bike first started playing up. It seemed to be running rough and was misfiring occasionally. Also my GPS kept crashing and locking up but other than that everything else seemed to be working OK. When we finally got out of the twisty stuff I decided to pull over to check my map and the bike just stalled. Then when I tried to start it nothing happened, it wouldn't even turn over. So I turned the headlight off, stuck it in third gear and while walking along beside it I managed to roll start it very easily. In fact this has got to be the easiest bike I have ever roll started. Much easier than the new fuel injected bikes which are next to impossible. So with the bike running I decided to keep going and try and make it to our destination. While traveling on the more open road it seemed to run OK but once we hit the twisty stuff again it would start misfiring when ever the revs dropped and was getting worse and worse. Then as we came into Healesville it stalled again while slowing for some traffic lights and would not roll start either so I rolled off the road into a nearby service station carpark only to discover that it was right in front of a motorbike shop. :D How's that for luck.

    [​IMG]

    Once parked I began pulling things apart to see what was going on. Due to having electrical problems with my KLR in the past I now carry a multimeter and wiring diagram when traveling on my bikes as well as numerous other tools so I had pretty much everything I needed already on hand. Initial investigations revealed the battery had gone flat so I bought a new one from the bike shop, stuck it in and gave it a try and the bike started beautifully but further investigation revealed that the alternator wasn't charging. So then I began checking and metering out the wiring loom connections for the charging system. Meanwhile the bloke in the bike shop stuck my other battery on charge so the I could carry it as a backup in case I couldn't get the charging system working. All the wiring checked out OK so I decided to pull the cover off the alternator and check the brushes etc.

    [​IMG]

    As I expected the brushes were fine as I had fitted new ones when I put this motor in therefore they have probably only done about 5000ks. What I did notice though was that the slip rings on the rotor looked a bit dull and felt and seemed to be covered in a thin film of oil. So I borrowed some contact cleaner and wet'n'dry paper from the guy at the bike shop and gave the whole lot a clean up then put it back together. Started it up and checked it with the multimeter and it was charging beautifully. So that was all it was and after fixing this the bike ran fine for the rest of the trip. Therefore the poor running problems we had with the the bike was due to the fact that once the battery stopped charging and started going flat there wasn't enough voltage to power the CDI and ignition system properly hence why it began misfiring and stalling.
    I am not really sure where the oil film came from as there is no signs of an oil leak in the alternator. But maybe the alternator shaft seal is starting to weep slightly. So now I am going to fit a voltmeter to the bike to allow me to monitor it more closely and see how it goes.

    All up it probably only took about an hour to get the bike running again so fortunately we still reached our destination with plenty of time to spare.

    [​IMG]

    Also I would like to say thanks to the owner of Healesville Motorbike Centre as even though i managed to fix it myself in the carpark he was still very accommodating and willing to help in any way he could.
     
  44. MarkV

    MarkV Member

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    thanks for sharing man. happy anniversary.
     
  45. adrian1

    adrian1 Active Member

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    Nice work...shows the benefit of carrying the right equipment with you!
     
  46. gunnabuild1

    gunnabuild1 Member

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    Happy anniversary to you both.You sound like a handy bloke to have around Trokel.
     
  47. trokel

    trokel Member

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    New Bike

    Although generally I was quite happy with how the bike performed on our Anniversary trip when I got home I decided it was time to buy a new bike, but not for the reasons you are probably thinking.

    On the way home from that ride we took a bit of a detour to meet up with some other people and this involved taking a gravel road through the mountains.
    [​IMG]


    I must say I was quite surprised how well the XJ handled it and even more surprised how much the missus enjoyed it. However as it is pretty harsh on the bike I decided that it would be good to get a bike more suited to this type of riding that could also take the 2 of us with a reasonable amount of gear.

    But don't panic I didn't get rid of the XJ.
    I sold my KLR instead.
    [​IMG]

    And bought this
    [​IMG]

    Now the XJ can have a bit of a rest while I get it ready for the racetrack as the Broadford Bike Bonaza is approaching fast.
     
  48. FJ111200

    FJ111200 Active Member

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    Copy cat :wink: Nice bikes.

    [​IMG]
     
  49. trokel

    trokel Member

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    Yes they are. :D
    Prior to our Anniversary trip i discovered that Triumph had a ride day on at our local dealer so although I wasn't looking for a new bike I figured that it couldn't hurt to take some for a test ride so I took it and a 1050 Tiger sport for a spin. After that I couldn't seem to get the it out of my mind but talked myself out of it as I couldn't justify spending that much money. But once we got home from our trip and after discovering how much the missus like traveling on the dirt I decided to take her for a test ride on it and she loved it so that was that. Part of the deal was that it came with free factory panniers which i am still waiting for but hopefully they will turn up this week. At the moment it is basically stock apart from the protection bars and screen both of which i made myself and i have just fitted a factory centre stand. Also I am waiting on some more aggressive offroad tyres as I plan to get it dirty.
     
  50. adrian1

    adrian1 Active Member

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