What did you do to your Yamaha today?

I forgot to mention... I also swapped out the boxy stock head light for a round head light from an XJ550. It's a perfect fit, though the wiring is a tight fit.

 

EVERY BOLT BROKE (except for one) ON THE CARB FLANGES! i drilled them all out, however 2 of them walked out of the steel bolt and into the aluminum head, and now i have a big mess to figure out.

 

tubes. pulls oil out and pushes dirt in. I get a very attractive line of dirt on each tube at the top of it's compression

 

I don't know if you can sand that out safely. If you replace the seals, it'll help for a while, but the pits will tear them up soon anyway, so that'll be about $60 (counting the dust seals) and a lot of work down the tubes (har har).

It might be worth finding out if you can replace just the tubes. I doubt that part can be bought separately any more, though.

Ask chacal. He's a member here by that name who sells lots and lots of XJ parts. If he doesn't have it, post something in the Sell/Buy/Trade forum. Also, hit Google, eBay, and BikeBandit. BikeBandit is probably the most expensive solution by far, but it'll be the right part.

 

When you are changing the fork oil add include about 1 oz of seal swell or an automatic transmission seal conditioner to the volume of each leg. This works wonders on keeping the fork seals from hardening.

I've used this many times over the years and if the seals are just leaking slightly this will usually cure the problem without replacing the seals. I also just use a straight 10 weight motor oil in fork changes.

 

I changed the oil. I dont think it had been done in YEARS! Felt good to do something myself to my 1st bike.

 

Lately I've been touching up the paint on the tank and plastic. Repainted my side cover emblem - mediocre results! Today I licenced it and took it for a 50 km. shake down ride. Everything is just fine. I added about 175 ml of Seafoam to a full tank of gas and I'll run it until it's on reserve.

 

well its been a while, so ill update....
recovered the seat (not bad for first time)
replaced front and rear brakes.
replaced air filter/ oil filter/ spark plugs and oil.

 

Well, got the o-ring fixed and the rich burn was the result of me not allowing enough slack in the cable (dumb a$$) which resulted in the enrichment being propped open a bit. I left work early Friday, got my temps, and registered my bike (donated almost $150 to WI DMV >>> OUCH!). Got home, fixed said o-ring, assembled everything and she fired right up. It was sounding good so I thought what the heck and took her out on her maiden voyage (with me). I only put about 3 miles on but she rode nicely and now I see why y'all like these bikes. I took her out again Saturday and put another 10 miles on the odometer practicing on the side streets around my house and once down a more major 6 lane road in traffic. I've got plenty more practicing to do, but this weekend was a good start.

I am replacing the mufflers on Wednesday so I won't wake my toddler up going down the driveway and that should help keep the neighbors at ease and richen up the air/fuel mixture a bit.

 

Put my father on the 650 to see if he could learn to ride a bike. Took him a little while to get used to it, but he got the idea after a couple of times around the circle. Might have to take him riding some more this summer!

Not ready to sell it to him just yet. Bike still has some quirks and I love my father too much to give him a quirky bike while he's still a newb. Maybe next year.

One fork from the parts bike still open, but no progress on it since. Freakin' job keeps interfering with my wrenching...

 

I got the exact same problem! :lol:

 

I don't know if this counts, but I worked on the Ninja and my Saturn today so I can mark those things off the to-do list and get back to the XJs.

 

Replaced the speedo light this morning.
Tach light crapped out on the way to work tonight.
:roll:
Found LED 194's at Auto zone, but they were "Super Bright".
Which meant there were 4 led's at the end of a 194 wedge base.
Much to wide to fit the hole in the back of the speedo.

Adjusted the handle bars, mirrors and controls to my liking.
Adjusted the clutch lever, needed to disingauge sooner.
Getting there slowly.

 

RODE IT!!

 

well,

redid a gasket on the floatbowl of carburetor 1,
bench synct the carbs
fine (well, more or less that is) tuned the sync on sound.
cut a piece of sparkplug cable for fourth cilinder to make it contact again

Than found out the petcock is leaking, tried to overhaul it, didn't work.

kept searching this forum, and i probably try tomorrow wether the o-ring is torn...

Last but not least, tried to get my headlight working again...
think I have a real bad earth with the bike... get a voltage reading of probably 3 or 4 volts with running engine, on both hi and lo beam...

The bike is a mess

 

Pulled valve covers and checked for sticking valve.
Removed exhaust(complete).
Pulled carbs and soaked in carb clean.
Pulled clutch for inspection.
Removed alternator and tested.
Swore a bunch of times, threw a couple of tools.
Made parts list....

 

Installed a pair of Harley mufflers last night replacing the stockers sans baffles. I was a bit afraid of how they were going to sound, but I was pleasantly suprised with the sound when I fired her back up. It wasn't that real mean grumble that it had, but more of a cross between a rice-grinder and a sport bike.

The installation wasn't too painful either. I removed the entire exhaust (I was lucky that all the nuts came off easily), cut off the mufflers so that part of them (3/8" or so) was still attached, used a cutting wheel in a grinder to remove the outside which was the muffler case leaving the inner tube which fit inside the Harley muffler. I then cut off the mounting brackets and bumpers and welded them onto the Harley units. Then I welded the mufflers onto the factory pipes. I am quite happy how they turned out and wish that I would have taken pictures to document. I'll post pics of the new pipes later.

 

I knocked out the fork seals on the wife's bike after work.

 

Drag Bars and Wind Shield



I mounted the drags down in the original clamps first but the clutch cable was binding and the wind shield hardware wouldn't work. So I picked up a set of Custom Chrome 4" pull back risers, caps and 1"-7/8" adapters. I had to drill out the bushings to accept the 1/2" mounting bolts. The brake cable required a little re-routing and I broke the the throttle cable elbow in the process(guess what my next purchase is going to be!) but it all came together rather well and makes for a very comfortable ride.
I should have fabbed a beauty cover for the triple tree when I had it off... Next time.

OH Yeah, Then I rode the hell out of it!

 

RODE IT! Finally got to put actual driving on it (been trying to learn slowly how to ride a bike). I went about 15 miles in each direction and she definately ran better on the way back. I am running Seafoam in the gas that I hope will do something (not sure what) and the new mufflers are performing very well. I definately like them.

 

Worked on the 750 some more, mostly disassembly and minor testing.

Finally got around to reterminating the wires for the fuse box on the 650 to take the replacement fuse panel, and I'm so glad I did. What a nightmare! Not only was the old fuse box coming apart (surprise), but the PO had done some really stupid things involving in-line fuses and electrical tape. Ripped all that mess out and had to cut into the wiring harness a little to expose enough wire to get the new box in, but it's in and it works now. Headlight, blinkers, and ignition still work, so it looks like that's set!

Continued pulling apart the spare left-side fork tube. It must be from an '81, since there's no air valve in the plug. Drained the oil out, but then couldn't break loose the bolt at the bottom that holds the damper rod in place (8mm hex). Sprayed it with some WD-40 and letting it soak now.

Bought some Seafoam a while ago. Need to find some time to run some of that through the 650. Suggestions on how much to add to the tank? 1/3 to 1/2 of the bottle? Seems like the entire thing would be too much for that small a volume of gasoline.

 

Its been a real productive day:

- Checked coil resistances

- Installed new valve shim on intake valve number one

- Tightened linkage to rear brake switch

- Adjusted pilot screws from 2-1/4 to 2-3/4 turns out

- Sync'd the carbs (without the YICS tool)

- FINALLY fixed my turn signal problem (they wouldn't blink), turned out I had to rewire the plug that connects to the relay (that took MONTHS to figure out)!

AND THEN: I rode it all around the foothills of the rockies until the sun had set.

Ol' Thunder is running about 100times better tonight then she was last night!

For tomorrow: Clean and shine everything, ride around some more!

 

Checked valve clearances (no adjustments necessary).
Installed new clutch cable.
Changed crankcase oil and filter, final drive oil, fork oil and air-cleaner element.
New plugs, brake pads and shoes.
Some cleanee-shinee stuff.
Covered 153 miles of (mostly) twisties on a three-hour ride.
She's running soooooo good! Absolutely flawless, in fact. 8)

 

Killed my battery trying to figure out why my turn signals werent working. Broke a shoe. Started hateing my bike again.

 

Took the bike out for my first ride (on a street bike).

 

Tore the carbs off the bike for a good cleaning.

Its raining out and will be for most of the week, its a good week for wrenching on the bike.

 

Yesterday I rode 45 miles, one way, just to have an A&W root beer float. The nearest A&W is about 10 blocks, but the float at the other one tasted better! :lol:

 

Yesterday I cleaned more wirirg connections, replaced starter solenoid, finally rode all of the half dead fuel out of it. Today filled up fuel tank, added 1/3 bottle seafoam, then let it run long enough to get through the system. Then I come in the house took allergy medicine and rested. Plan for the coming week is to get it legal (tagged, insured), get my permit and ride. Fingers crossed.

 

Installed gauges from PainterD(thanks buddy)
Cleaned wiring connections in the headlight.
Rode to Austin, TX.
Started Colortuning. #4 is buggered before I even began.
#1 was a good screw. #2#3 both were dirty screws(didnt wanna move)
#2#3 need replacments, Stainless allens anyone?
She went from a hot burning lean race bike, to a rich coasting crusier bike.

 

I installed a new halogen silver star headlamp, works great. Then I installed a new speedometer gear, and now have a working speedo!

I am also looking for header pipes and possibly a collector for my 81 XJ650. If anyone has any pm me. They do not have to look that great, but they cannot be rusted out, because I will be covering with header wrap.

 

pulled the resonator cartridges out of the exhaust. Sounds like my 01 FZ1 now. Amazing!

 

I was up till 2:30 this mornign gutting out my carbs again to get at those things I misse dthe first time I cleaned them. Got everything don this afternoon about 5 and put it back on and noticed an improvement on how it ran! In my opinion it seems to be worth it! Thanks RickCoMatic for that nice walkthrough you typed up here awhile jgo on cleaning carbs! Seen a few things there that I missed before. Also Just incase anyone wants to know I found that the screws that hold the carb bowl on work great to get out the emulsion tubes, fit perfect! You may already know that but if not there you go! FWIW

Edit: sorry about the spelling! didn't get much sleep last night!

 

Took a guy who works for me out for a ride. Me on the CBR, him on the XJ650. Had some fun, until he crashed the XJ. Came around a tight poorly-marked 35 mph turn too fast and he went down on the right side in some grass and gravel.

He's okay. Cut his knee a bit and has some rash. I think it's mostly his pride that was hurt.

Bike is a bit bent up. Got her upright to find the blinkers and headlight were a mess. Needle on the tach snapped off (though the stub that's left works fine!). Steering is way off to one side as well. Not sure what is causing THAT. Some extra rash on the engine; YICS emblem missing now; dent in Kerker exhaust deeper than before.

Started right back up, though. Ha! That impressed him and the other two guys we rode with. I told them the XJ is a hard to kill bike.

Rode it all the way back to town (20 miles or so). He bought me coffee and offered to help pay for parts and/or machine stuff as necessary (which he *is* capable of doing). We'll see how that goes. I just hired this guy a while ago and he seems like the stand-up sort. We'll see for sure now.

Got her home and started taking the front end apart. I have pictures that I will post soon of the damage. After getting the wheel and fork tubes off, I don't think that's what's bent. They look perfectly straight now that they're free, and holding a ruler up to them seems to confirm this. The twist in the triple was pretty pronounced, so if it were the tubes, I think I'd be able to see it.

I think the bent headlight shell and/or the steering stem itself (upper vs. lower) is what got yanked out of true. I have to get the entire instrument cluster apart anyway, but I got interrupted just then so it'll have to wait.

*sigh* I was just getting this thing in really good condition. Ah, well. I needed an excuse to replace the steering bearings and some other things anyway, I guess.

 

Sorry to hear that rhys, make him work harder now LOL glad to hear hes ok,

 

Yeah, we checked him out. Fortunately, he was smart enough to wear a good jacket and helmet, and he borrowed some gloves which saved his hands (the gloves got some rash).

He was ticked about his jeans, though. Apparently, they were some really good jeans that were hard to find (for him, anyway). Not designer or anything, but they fit *just right*, and now they're torn up.

He called me later after he caught up with his wife. She threw a fit. ;p

 

I put a lot of thought (and read a lot of posts) before starting Seafoam in my gas to gradually clean varnish/residues/etc. Even though I installed a new inline filter to catch particles loosened in the tank I was concerned by comments on problems arising from grunge possibly loosened within the carbs.

So rather than a big initial dose of petro-laxative, what's working for me is a couple of ounces per tankfull (as described in Seafoam 'gas additive' directions). No problems whatever so far (4 tanks)and I feel it's gradually cleaning out all the old buildup.

Your call, of course: if you hit it hard with a heavy Seafoam mix upfront that will clean it fast but I'd be prepared for a slight risk this may require going into the carbs.

 

That is why I took the time to clean out my carbs first prior to adding the SeaFoam. I know that I didn't get them perfect or pristine, but they were quite clean and how new viton seals throughout.

Food for thought... :wink:

 

I rode mine to work today for the first time. It has been quite cold this spring and this morning it was finally above 45 deg when I left so I figured it was about time I started riding. Plus, let's do a little math:

1997 Chevy Suburban = 10-12 mpg city
1982 Yamaha Maxim 650 = ~35-40 mpg
Gas = $3.95/gallon
Fresh air = Princeless

 

Had a fouled plug (probably from the extended time I've spent tinkering with the carbs) so before I left for work in the cage this morning I threw four new plugs into the bike. Hope to fire it up later tonight to see if that helps my issues. Fingers crossed.

 

Finally experienced my first running out of gas moment riding around today. So, for tank #1; 80 miles and ~2.19 gallons. I say about because I don't think that I filled her up to the bottom of the neck the first time. So that makes the first tank's milage at least 36.5 mpg and that is all city driving with the first 30 miles or so spent learning how to ride her in my subdivision and some redline moments, not many though.

I changed the oil (finally) tonight also and refilled her with Rotella T 15W-40. The PO definately put some wrist into the filter housing bolt but it did come out after a bit of persuation.

 

Pulled the forks to do the seals and got in way over my head. 82 xj750 forks are overly complicated.

 

Went to a Junk Yard ans spent 2-Bucks for a couple of quality Spark Plug Wires off a wrecked VW Passat.

Came home and pulled my 1~4 Coil and did "Coil Surgery"
Replaced the Spark Plug Wires on my left Coil.

Ran the Bike.
Good solid Spark to 1 and 4 now.

 

Mmmmm... Fresh wheel-bearing goodness!

Well, the front wheel at least. It really needed it! Maybe do the rear wheel next week.

 

Changed the oil, filter, and rear end grease.

 

I just bought mine today. Now I just need to do a little work to get it where I want it before I hit the road.

 

I took off the front fender n both side covers. N started sanding! I bought flat black "spray" paint. 2 paint my bike with! I'll be making a post of my progress soon.... :twisted:

 

Continued my assessment of the damage. Front fender: bent. Exhaust pipe mounting bracket: bent. BRAND NEW HANDLEBARS: bent. (Well, they were used, but I just got them from chacal a couple of months ago.) Right front blinker stay is a little bent, but servicable. Headlight shell, bracket, and ring are toast. Add those to the list of busted things mentioned from Sunday.

The good news is that I think the forks and clamps are okay. So far, not counting rash, everything that was damaged is a fairly easily replaceable part, assuming the parts can be found for sale.

Good news part deux is the fact that the guy who bent it has a lathe, a mill, and a drill press. What can't be replaced might be fabbed (like that mounting bracket).

 

I've tuned the engine on my 750 Seca before with no problem, but it never seemed to run glass smooth...till now.
I've always blocked off the YICS ports with a tool I made to synch the carbs.
So I read here where it's not etched in stone that you need to block off the YICS ports to synch the carbs, so I figured I'd give it a try. I am convinced, you don't need to use it. I have the bike running like butter now! It starts with almost no effort (no choke) and idles like new. It revs smooth thru the power band. It's almost like a different engine now.
The carbs were not off by much, but evidently enough to make a difference between idling rough until it warms up and a little hesitation when reving it - to - starting easier, idling like a new motor and reving effortlessly thru the gears. My air screws are re-adjusted out 2-1/2 turn now and it seems to be perfect.
I never had a Colortune to set the carbs, so I do what I can with what I have. The plugs look good too, so I must be as close as perfect as I can get without it. PD

 

A little late... Monday... Went to drill out the stripped screw in the MC so I can change fluild and such...... well drill caught and snapped the head off flush with the body...no hole had to be drilled... cover now using 1 self stapping screw :/

After that check the bleed valve to find it was stuck... hit it with some pb blaster (careful as not to get the rotor or pads) wating game is on.

Checking local &deciding what to order, may hit Mikes SX for some SS braded line and new levers & grips, checking into a local Virago 920 parts bike on levers and maybe MC, if the price is right and they work....

 

There is enough material on the threaded body of the MC to drill it and tape it for the next over-size.

You just have to drill the Cover for the over-sized fastener; too.

I had to do this on my 750 Maxim. Both Cover Screws broke-off while I was trying to uncover the Master Cylinder to flush the brake fluid. I drilled the MC receiving threaded ports to the next over-size and rant the drill through the two holes on the cover.

Then I tapped new threads in the MC receiving holes and now use Stainless Steel Cap Screws to hold-on that cover.

Looks good and don't leak!