What did you do to your Yamaha today?

took the starter apart and cleaned it. it was dirrrrty.

 

wednesday-lit it on fire
today-lookin for a new tank

findind and waiting for a tank will give me time to prime/repaint some of the frame, which is good in a sense becuase i'd always choose to ride it ahead of work on it

 

Painting a 750 tank.

 

Painting a 750 tank.

 

Pulled the seat and tank and am about to check the valve clearances! Wish me luck, lol. Thank God for the how-to's on here about the subject, woo-hoo!

 

Re-built the front forks and installed Progressive Suspension springs.

 

Getting a new to me XJ 750 tank ready to go on my XJ 650.
Currently it needs to dry dry dry and then I will start knocking the orange peel off with buffing compounds. After that, lots of clear coat.

 

Looking good BillB! That clear coat will really set it off! Are you putting the yammie emblems back on?

 

Finally tracked down the source that's been giving me a SLEW of problems -- the clutch!

I developed a knocking noise that I though was an out-of-sync/lean motor, except it wasn't near the cylinders, and it goes away when I pull the clutch at idle. Rats! Also when holding the throttle a good bit in neutral (4k or so) there would be an unusual vibration, which would mostly go away when I pulled the clutch. Double rats! I also noticed in the past couple weeks there wasn't quite as much pull out of first and second gear, and it felt almost like it was losing power for brief moments but the engine would still accelerate like normal. The clutch wasn't really slipping like a slipping clutch would, so I wasn't considering a clutch problem, more of a carb/top end problem. But given the other symptoms, I'd say it's safe to assume the clutch needs attention.

Point being, tonight I started the clutch rebuild.

 

Just rebuilt my clutch as well, now it stalls when I shift into first, lol, hoping Fitz or someone can give me some guidance. Did you have to search for neutral as well?

 

finally looked at my gas tank since the horrible night. The paint on the tank looks pruney, but I think the tank and petcock are still okay. we will see

 

Finally got the carbs back on after cleaning and bench sync. I didn't lose my temper.....much.....well ok I sort of did. I'm glad Mr. Yamaha wasn't there because I probably would not have been nice to him. Those stinking intake boots! There is no wonder there is so much discussion here about pods. Anyway, they are on and it fired right up and actually idles at 1100 rpm without dying!!!! Thanks to all who wrote tutorials. Couldn't ride tonight, still rainy here but tomorrow afternoon I'm planning to test ride and then on to the sync.

 

Got my new battery and new ignition switch (26.50 on eBay) in the mail today. Installed the switch. Cleaned the battery box up. I'm waiting for my wiring harness to get here and then will fill and charge the battery.

I also ordered two proper ignitor boxes , a regulator and the mounting panel for them off eBay. Just under a hundred bucks for all four parts. I figure at less than $50 each if both work I have a spare and if only one works I still spent the curret ball park average for a used one on eBay. Both came from reputable sellers.

This weekend I'm going to start on my initial pass at the carbs and fire up the blast box to strip the tank and the headlight housing as well.

Got a line on some possible switch module/pod replacements earlier today as well. Are the 80 750's the same as the 80 650's?

Sun going down so time to come inside and build a new racked PC for the studio. Always something around here to tinker with. Life is good.

Will post some pix of the bike in it's initial new to me state later tonight or tomorrow.

 

Nope, it shifts and engages just fine, I can just tell there's something loose.

 

Yesterday evening I reset the air mixture screw to 2,5 turns out. It really changed the bike's behaviour, to the point that I had to use a bit of the idle screw to get to idle right.
Still getting a bit high RPMs when the bike is really warm, but not nearly as much as I used to...

 

Replaced the jerry rigged start button I had previously installed with the correct one from Len. Disassembled the starter solenoid, repaired broken wire at the coil, dressed the contact area. Starts first touch now. Used to click, sometimes not engage at all.

 

Clutch maintenance today! Man this is way easier than I thought it would be. Although I need to get the hub off, and must acquire the drum holder pliers.

 

Made a single seat out of an older seat pan... hacked, padded and wrapped with covering from Kawi vulcan.

 

Finally finished changing out the clutch plates and springs. Was a big pita and I'll need a new gasket now (from installing/removing the clutch cover so many times), lol, but so worth the fight! I was so pissed at one point I almost got washed up and rode to the dealer to buy a new bike, lol, big mistake that would have been on the $ wallet.

Mac

 

Ordered new valve cover gasket parts from Chacal.

Switched to "classic" throttle position based acceleration enrichment, and really lowered the added fuel curve, which finally got me to some quick, crisp, response when stabbing the throttle from idle.

 

I can't do anything today.... waiting for rear brakes, throttle shaft seals, + some replacement butterfly screws

 

Took her for a 115 mile ride in glorious North Yorkshire (and it was sunny all day).

That's the reward for all the spannerin'!

Nige

 

Fixed the flashers (relay was loose), put the speedo cable on and it screamed when test riding - will check cable or odo gears tomorrow.

 

painting the plastic piece that says Yamaha and goes around the key ignition thing. nice gloss black looks alot better than faded old black for sure

 

db1985 it's not the odo gears, it's the input shaft bushing or the cable. Take a look: http://xjbikes.com/Forums/viewtopic/t=15303.html The odo gears turn too slowly to scream.

As for what I did to my Yamaha today: Wiped the garage dust off, checked the air in the tires, had a poke at the chain (it's fine) and I'm about to go for a ride.

 

thanks bigfitz52...those pics are great.

 

I needed the clutch basket holder toola-ma-thingy, and Len/Chacal was kind enough to meet me with it (and a Colortune I bought). It was nice to finally meet you, Len. Much appreciated.

Promptly went home and got the basket off. The current sad state of my XJ:



Teeth seem to be in good shape:



Primary gear has no tooth damage, the transmission spindle roates smoothly with no play of any kind:



One step closer...

 

I'm new to this so pardon my ignorace, but how does your XJ look like a sports bike compared to the cruiser types as most?

 

The Seca II is the next era of XJ, which they made from '92 - '98.

Not as much power as the 80's era XJ's, though!

 

that would be a Seca II as opposed to classic Seca 750R and 650R sport tourers. you're probably more familiar with the Maxim cruiser. XJ's come in all shapes and sizes, same fundamental motor architecture (aircooled inline 4 with YICS) Oh and I'd be remiss if I left out the 550's... then there's that watercooled one...

not "today" but very recently put on a maxim throttle and switch cluster to accommodated an R6 master cylinder. obligatory brake flush/bleed. A quick test ride followed by checking fork air and going to 17psi and set anti-dive adjuster to 3.5 / 4.

 

I guess while I'm on a picture spree...

Other Seca II owners have said that this pin that keeps the oil pump gear from spinning wears out and the gear starts to rattle. There about 5-6mm of play in the gear.



Do you know how annoying it is to remove this clip without the proper pliers?



With the oil pump gear removed:



Oil pump gear and fastening accessories:



Not sure if the little dowel has worn out or this little hole has become larger. Hard to imagine either. Gonna see if the manual says anything about it.

 

currently wiping down the petcock/tank to see if they are truely saveable. The petcock was black with soot, but looks good after a good cleaning. the tank has some work to be done, but nothing that can't be fixed with my good arm

 

Further tweaked the warm-up and acceleration enrichment curves. Then took her out for a few miles of test run on the highway. Pulling like a rocket at all RPMs! I'd like to keep the Atari, since it seems like a core part of the bike's original personality, but, man that speedo maxes out quick... and the tach isn't all that happy with a modern coil driving scheme either (gets a bit twitchy between 6 and 6.5K).

 

Was too lazy to change the oil and filter before winter. But now I've got it changed after the first 1000 km this season - Castrol 4T GPS 15W50. So with my 'new' carbs, fresh oil, valve clearence adjusted, carbs syncronized its running like a new bike - smooth and easy. AND new seat covers and foam + paint job this winter - nice
Damn I like to ride on a bike in the spring time.

 

Finally got around to putting my new tires on. Shinko Podium 006. Good reviews, cheap enough.

Went from 110/70/17 F to 110/60/17 F

Went from 140/70/18 R to 150/60/18 R

Lower profile, a little wider. They look good! We'll see how they handle once I finish the clutch.

 

Well I nearly had a heart attack at what I found on my XJ750, I go and drain all the oil out as it was time for a new filter change, I took the filter housing off and jeez! I cant believe what I see, the last time this had a filter change was by a bike workshop and I'm telling ya, the right way as it states in the manual is: Housing, then spring, then washer, then filter in that order right? So on examination of what the garage done was.... Housing, filter, spring and no washer!!! WTF you cant even trust a bike workshop to do the job right! And they even lost the washer!!

Oh yeah this is what she looks like after the restoring over the past few weeks, just waiting for the new bars and exhausts to be delivered now...

 

Added some new tank badges. Changed fuel filter. Went for short 20 mile ride.

 

finally got the bike registered again. fixed fuel leak, painted ducktail/sidepanels, dumped oil that was somehow 2lt over capacity, and gave it fresh oil. then took it for a celebratory ride around town

 

Changed the oil and filter. Then went for a little ride to get the new juices flowing.

 

Clutch finished, put a new gasket on tonight since I ruined the one I ordered for this job by taking the cover on and off too many times. Hoping the weather holds out so I can ride it to work in the morning.

 

Installed the new fuel petcock that I ordered a couple months ago. Plates will be renewed tomorrow then I can go for a ride after work.

 

- Oil and filter change
- Cleaned exhaust headers and repasted them into collector box
- Cleand carb-to-engine manifolds
- Discovered fuel leak from the V-rings at linkage

Odin dammit

 

gday, changed engine oil and filter, new clutch cover gasket then changed the diff oil, discovered a screw in back tyre so went to get new tyre(old one worn down to wear thingos)then got rear ended (lucky i was in my car) by a van, now car will be in the panel beaters for a week, shouldnt have changed my oil,could be worse i guess.

 

Took my second set of Atari gauges apart to sand and paint the rusted steel gauge dividers. Used rust-converting flat black. Also painted the faded tach and speedo pointers with Testors gloss enamel orange (#1127) model paint. Will install two red 5-led assemblies for general gauge illumination when I reassemble.

 

- installed new battery
- found out that replacement blinker unit I bought only works with a fresh battery
- reinstalled tank
- cranked her for the first time since January and let her spin a bit
- drilled out broken bolt from rear drum brake pinch bolt (I snapped it because I had no torque wrench at the time)
- replaced bolt

- tomorrow I have to renew the insurance/registration and take it for a test ride on the new tires

 

That washer seems to be a pretty commonly lost part. Found it was missing last time I did an oil change too.... Not sure whether I lost it that time, or the time before, or if it was already missing before that. Nice thing was it was easy enough to make a suitable one in the mini lathe.

 

Rode it to work and back, and to lunch and back, then, later...

Washed the engine with some Foamy Engine Brite and the garden hose. Then installed a new valve cover gasket and donuts. However, the LF hold down bolt wouldn't reach torque (7.2lb-ft), so I may have to have that cover back off again in the near future for some Helicoil work.

Also tightened up the exhaust header nuts - one pair of which was quite loose and I had noticed some blow-by noise there.

 

I dropped my Yamaha off at a local shop. For 335 The carburetors will be completely cleaned/rebuilt and the clutch will be replaced. I was going to do these things myself but it would have taken far to long, and I have the itch to ride. All I have left to do is buy two new tires and it will be 100% road worthy again.

 

I'm just about done with a carb rebuild for an xj650 maxim. Just for fun, and for my own knowledge base ( and so I face the carb demon square in the face) I decided to do a COMPLETE carb set teardown and cleaning. I mean COMPLETE.....not a single piece was connected to another by the time I got it all part (except for the diaphragms still connected to the slides). Every single piece was cleaned, every port and hole cleaned, even the tiny screws as best as could be. It's now back together and ready for bench syncing---Actually, it was pretty fun, I have pulled up a second rack to do next.

Dave Fox

 

Ordered some new tires (Dunlop 501's). Currently have K591's. Back one is down to the wear limits and both are about 12 years old.