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XJ550 restoration

Discussion in 'XJ Modifications' started by Qatar, Oct 19, 2007.

  1. Qatar

    Qatar New Member

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    Hello all

    The first time I visit this web site by chance , I was search for parts and I find this forums , it's look like family .

    My cousin have XJ550, but I don't know what the year they mad it , he didn't drive it or start it more than 15 years ago .

    It was in out door and Non storage, he told me he want to drive it again and he was sorry cause he didn't keep it in the store, I told him I will tray to do restoration for it and I start work today , I get the bike to my home and start to disassembly ( seat , fuel tank , carburetor ) , the bike in horrible condition and I think it's need at least 2 months to finish it .

    Just to know this is first time I work with bikes , I'm just beginner (hobbyist) in car Engines .

    Will accept all advises 8)

    (Sorry for my accent but I'm from very far country)

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  2. dubyaohohdee

    dubyaohohdee Member

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    Wow, i picked up a free 80 Xj650 a couple of weeks ago and compared to yours mine belongs in a museum. Good luck on the build though. Please take pics as you progress.
     
  3. Gamuru

    Gamuru Guest

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    Oh my! 8O
     
  4. blackdiscoball

    blackdiscoball Member

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    Yeay good luck. Hopefully those pictures make it look worse then it is. I dont have any specific advice except have fun with it!
     
  5. Gamuru

    Gamuru Guest

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  6. Gamuru

    Gamuru Guest

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    I almost forgot. The VIN for the bike should be here on the neck. Post that and someone here should be able to look up the year of the bike.
     
  7. SaltyCITYXJ550

    SaltyCITYXJ550 Member

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    My advise is to start by putting it back together and pressure washing it off. That is a really, really dirty bike. Take a bucket and soak those carbs in gasoline (petrol) and let them sit for awile. Then totally rebuild them. All the rust on the frame can be fixed by a total tear down and have it sand blasted and powder coated. I'm not sure what you want to spend, but based on how dirty and rusted, you are going to have some money and time invested.
     
  8. redneckzombi

    redneckzombi Member

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    Looks like you've got your work cut out for you -- good luck! I can imagine that thing's pretty much been sand-blasted slowly for about 15 years...
     
  9. Ltdave

    Ltdave Member

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    well right off the bat i can see your problem...

    you need a new fuse box :D


    seriously, i would say it is probably worse looking than it is mechanically. as long as the air cleaner cover was on, there shouldnt be any foreign matter in the engine. it will take some elbow grease but ill bet you can get it cleaned up. make sure you get the manual on CD, and get some paper tags on wireties. tag everything as it comes off the bike and keep things together. there is nothing more frustrating than to start putting it together and having extra parts or not enough parts...

    keep all informed of your progress...


    d
     
  10. redneckzombi

    redneckzombi Member

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    The paper tags on wire ties trick is super-useful. I did that restoring my old truck when I was a kid, and it helped immensely. If part is to small to tag or doesn't have anywhere to attach the tag, plastic baggies work well too.
     
  11. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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  12. RickCoMatic

    RickCoMatic Well-Known Member

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    You got a monumental feat ahead of you!

    Put those pliers away for a few minutes and start with a Bucket of soapy water, sponge and hose!

    Good luck.
    These bikes are hard to kill.
    I wish you the best in your effort.
     
  13. Nick

    Nick Member

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    Welcome to the site Qatar and good luck on the rebuild, looks like most of it's there, just dirty! It needs some T.L.C. ( tender loving care )

    I agree with the pressure wash before tear down comment, not too late, just plug all the openings to the engine and spray her down!

    I would also pull the spark plugs and get some oil in the cylinders to help loosen the pistons up, 15 yrs is a long time for it to just sit.
     
  14. dinoracer

    dinoracer Member

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    At least the rims look like they were freshly sandblasted :)

    Seriously you have some work ahead of you, hope to see the final product

    Sean
     
  15. Qatar

    Qatar New Member

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    Hello all ,

    Thanks for all your advices and furor .

    Today after I writ this post , I went to bike back and I start to dissemble the (Exhaust and engine ) .

    It's to hard and I get many troubles with open screws, the most of screws is rusted and broken, so the tool what I need to use the hammer .

    The engine removal take around 2 hors . the ground wash take 20 hors :roll: , tools clean take 30 mints .

    Tomorrow I will remove the (steering , wire harness , lights , signals , wheels and all other accessories ) .

    I will send the chassis, fuel tank, and all parts need to paint it with black color to work shop and they will do sand blasted and will paint it . ( it's will take from 4 to 6 days ) .

    I find many parts in eBay , I buy many things and also I order some parts from this site : http://www.crc2onlinecatalog.com/ .

    So what I have to do right now is :

    - wait for all parts arrive ( it's will taken tow weeks )
    - clean the carburetor
    - clean all rust parts
    - clean the engine and change the gaskets
    - re- chrome all parts that need ( it's may take 3 weeks cause I have to send it to other country )
    - clean and check the brake system
    - assemble all parts and accessories

    If there any site have parts for this bike pleas write it here .


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    Will back and will chat with you all you guys :oops:
     
  16. RickCoMatic

    RickCoMatic Well-Known Member

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    Don't neglect to knock-out the Carb's Emulsion Tubes. The Brass fitting you show in the photograph where you have the Main Jets removed are pressed-in from the top.

    You must force them out and clean the individual metering holes which surround its outside diameter.
     
  17. Nick

    Nick Member

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    Hope you ment to say "guys" not "gays"... totally different meanings! :lol:

    These bikes are pretty much on their own for parts.
    Some parts are still available direct from Yamaha.
    I spent a lot of money on ebay for parts that are no longer available.
    Other online sites are selling parts, some examples are....

    http://www.bikebandit.com/partsbandit/default.aspx
    http://www.denniskirk.com/jsp/product_c ... tid=378302
    http://www.z1enterprises.com/default.aspx

    From another thread on our site you can find some comments on some dealers here….
    http://www.xjbikes.com/Forums/viewforum/f=15.html

    Part diagrams are online at Yamaha here...
    http://www.yamaha-motor.com/sport/myyam ... there.aspx
     
  18. daveflick

    daveflick Member

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    isnt there a file upload limit? I'd love to see the end of the project and don't want you to run out of file space.

    Great work dude!!!
     
  19. Ltdave

    Ltdave Member

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    DANG! those carb floats sure look nice and new...

    i got a set of parts carbs and the floats were rather nasty. REALLY nasty compared to these in pic 2 of group 2...


    dont get the frame painted get it powder coated (if you can) shouldnt cost too much more but will be a lot more durable. unless your nothing like me an can keep from tearing up something just finished by reassembly...\

    good luck...

    david
     
  20. SaltyCITYXJ550

    SaltyCITYXJ550 Member

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    Just an opinion in having worked on a few things in my life. Stay organized as possible! I see that in the bottom picture you have many parts spread all over. I see carb parts mixed with engine parts, and a bunch of other misc parts. You will want to keep all of the carb parts together. All of the engine parts together and so on. One you have removed a screw or a bolt, nut, or anything, put it back in the hole it came from, the bolt it came off, etc... This will make putting this bike back together a dream. There is nothing worse than getting something put together and relaizing that you left a bolt out of something it really needed to be in. Then you undo all that work you started and redo it. It's so much better to do it right the first time. If you had a hard time gitting those exhaust manifolds off, you need to tap the cap screw holding it in place with a hammer. Nothing too hard though. That will help loosen those, or really any to speak of. Oh yeah, and get that engine in a plastic bag or something where debis can't get into it. Sand+Engine+friction=bad, bad news!!!
     
  21. Timetonut

    Timetonut Member

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    In India, that bike has probably seen a monsoon season or two. When I first looked at it (at the first pictures) it looked like just cleaning and the basics, but if it was outdoors for all that time. It's way beyond my skills. I also assume that with that much rain it may have the same issues of being underwater. Anyone have a bike that is from lowest Missippippi or other useful history for him where water would have gotten everywhere?
     
  22. Qatar

    Qatar New Member

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    update

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    will back shortly​
     
  23. RickCoMatic

    RickCoMatic Well-Known Member

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    Boy ... talk about BIG Jobs!
    That's a HUGE Job you got going, there.
    Good luck with it. I hope you can get those forks repaired.
     
  24. PghXJ

    PghXJ Member

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    did that thing sit out in the desert or something? It looks like it was sandblasted and soaked in the 130 degree Fahrenheit sun or something...

    Good luck man, you have an enormous task ahead of you. Just take your time. You will need to go over ALL of the electrical and probably will end up replacing a lot of the components.
     
  25. Qatar

    Qatar New Member

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    Thanks for communion, I will post all my progress pictures .

    Thanks a lot for this, no it's not under the water but we have very hot summer + humidity , so if it's under the water will much better, I didn't find the VIN number but I will search again .


    I wash it 3 times before I start work and I start to take the pictures after wash , as you see I start to remove the rust , the money dos not matter , all that I care that I want to restore this bike, at lest I have good time with this work . thanks for communion .


    Thanks for communion, I start to sand-blasted .


    you really axiomatic, how do you know it's only Fuse box ?? 15 years we are looking for the problem and you get it with little pictures ? amazing 8O

    I already find PDF file about this bike , it's showing many things but the problem that I need another 15 years to read it all .
    I will tray to get some one from Yamaha dealer to help me when I start assembly and have some problem, I hear there is one guy he work as technical more than 35 years, and he professional with 550 but I hop he still remember this bike . thanks for communion .


    This important advice, I do as you say and really it's will help . thanks a lot :idea:

    thanks , will back to you when I start to assembly .


    I already did , thanks for communion .

    Thanks a lot for your advices .


    etc .....
     
  26. Qatar

    Qatar New Member

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    Thanks for your advice, I will cleat the curb's with carburetor cleaner only .



    you must correct that word with privet message :oops: . any way I'm sorry for that corrigendum :roll:
    thanks for correction and sites .


    Don't worry about files , I upload it in my site .

    Thanks for interest .


    Yes, you right .. I do some mistakes from binger beginning ,, I will tray to correct it as you say, thanks a lot . :idea:


    What do you mean with (In India ) :?: :?: :!:


    I wish to , thanks for communion .


    Yes man , my country is very hot in summer . thanks
     
  27. Qatar

    Qatar New Member

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    In this week I start to sand-blasted the chassis and some other parts .
    I don't know how to dissemble the front steering …..
    I dissemble all rear parts and wiring .

    I have some trouble with my garage, so I will start to organize it with next week .

    any one can help me to find chroming equipment , I want to chrome the parts in home, so I need the equipment and some lesson about it .

    just to know , i'm from Qatar , so my nick name is same my country name .
     
  28. Gamuru

    Gamuru Guest

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    For those of us in the crowd who are geographically challenged, here's a map of where Qatar is...

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    It's a peninsular nation adjacent to Saudi Arabia surrounded on three sides by the Persian Gulf.

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    Doha, I believe, is the seat of power for the nation.
     
  29. Timetonut

    Timetonut Member

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    Sorry about that Qatar. In english the letter Q is almost always followed by the letter U and when I was looking up to find out where you are, I looked up Qutar instead of Qatar. I have since learned that they are totally different places, different zones of weather. I am sorry to add to the confusion.
     
  30. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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  31. Qatar

    Qatar New Member

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    thats fine bro ...


    whay it's nasty and dangerous ?
     
  32. Robert

    Robert Active Member

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    Those fork tubes are shot, new ones are in order Qatar. You have picked up a quite a lot of work. Best of luck to you on this project. Have you ordered up the XJCD set yet? A good investment for information on how it all goes back together.
     
  33. SaltyCITYXJ550

    SaltyCITYXJ550 Member

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    I would send off those parts, but that is just me. Doesn't look like you can get very big parts in those buckets. You'd be hard pressed to fit that front fender in a 5 gal bucket like that.
     
  34. Ltdave

    Ltdave Member

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    i was just making a joke. there is GOOD advice to be found regarding putting in a new fuse box or fuse holders...

    just a joke...

    d
     
  35. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Toxic chemicals used and noxious gases produced during the process....
     
  36. GreaseMonkey

    GreaseMonkey Member

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    that bike looks familiar! haha good luck, Looks like a fun time!
     
  37. Hvnbnd

    Hvnbnd Active Member

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    I just looked into this thread and my 1st impression from the pics and the forks was, sea salt.

    Man what a HUGE job!
    That engine and tranny had better have worked very well to have warranted all that work!


    Best of Luck
     
  38. Qatar

    Qatar New Member

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    Hello all ,,

    Sorry for late but I was out of country and organizing my garage take some time …..

    In this week I start to dissemble the engine and wire harness and clean the some parts ,, I got many trouble with the engine and the I need to buy ( piston ring ) but I don't know were can I find it , so if any one have web sit sale the piston ring pleas post the link ,, if any one here have it and want to sell it pleas post it in eBay and I will buy it from there ,,

    Will leave you with pictures …



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  39. RickCoMatic

    RickCoMatic Well-Known Member

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    If I didn't see for myself what a massive job you have going, there, restoring that 550 ... I wouldn't believe it.

    I will help you find the Piston Rings you need for your bike.
    Complete set?
    Standard or First-over size?

    You need to supply the exact data for the Rings you wish to locate.
     
  40. Qatar

    Qatar New Member

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    yes complete set , stander size
     
  41. Qatar

    Qatar New Member

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    it's fine man , I'm taken fun with this bike but the mean problem the parts , second problem the time .

    I really like to see this bike work again with good condition
     
  42. Hvnbnd

    Hvnbnd Active Member

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    Just noticing how rough that #1 piston and cylinder and head was.
    Did it sit with the plug out in the weather?
    Looks like a lot of corrosion in that hole?!



    Lots of luck there
     
  43. Gbambeck1

    Gbambeck1 Member

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    Wow, now that lools like a project!
     
  44. jeepsteve92xj

    jeepsteve92xj Member

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    WOW what a project for sure! Way more work than mine!

    I'd bet on that exhaust valve being in the open position all that time and just salty atmosphere. The intake has the carbs and that butterfly and slider system would keep the air out.

    Steve
     
  45. stereomind

    stereomind Active Member

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    With this much dedication... I have no doubt we will see some pictures of this bike when it's up and running. Good luck, Qatar.
     
  46. kellenholgate

    kellenholgate Member

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    this is sick. good luck. Makes my winter projects look simple..
     
  47. steveralls

    steveralls New Member

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  48. Cheesy

    Cheesy Member

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    WowZaas !!! Good on ya for taking on such a project on !!! If this doesn't give you a great sense of accomplishment once complete....I don't think anything will !!! Can't wait to see it apon completion! 8)
     
  49. jeepsteve92xj

    jeepsteve92xj Member

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    I, for one, would like to know how your project 550 is coming along.

    Steve
     
  50. Qatar

    Qatar New Member

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    topic back to live again

    uploaded the photos 8)

    sorry for breakup :oops:
     

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