XJ650RJ Seca Build

I'm doing the motone switches. They look just like the motogadget but slightly slimmer.

 

Cool. Yeah they look great and I'm sure they function well... I 'm not sure I can justify 100-200 bucks for buttons... hah We shall see

 

Small update. The wiring it taking longer than excepted with balancing work, and life. Hoping to spend the weekend finishing it up and getting her to turn over again.

I've got all the lights and switches hooked up. Now to include the ignition system and cleanup the wiring.

 

Visit/join our Seca650 Facebook group. Share and get model-specific help.
https://www.facebook.com/groups/307049559651392/

 

Just finished the wiring. Still need tidy up everything, but everything works as it should.
Now to go through the motor and ingition to make sure everything is getting power where it should. First few attempts to start the bike left just the starter cranking.

 

So this last weekend is marked as a success. I was able to finish the wiring, and get everything cleaned up. Also installed the new gauge. One of the "eBay special" gauges. I was able to get th bike to run and took it around the block for its first ride in almost 6 months. I still have some work to do with adjusting the carbs. But a ton of progress was made.


Wiring looks a lot cleaner than the last photo


New bar setup. I love the low profile of the switches and the single gauge. I've heard a ton of stories of people not being able to get these units to work but everything is working.

Final photos to come once the bike is tuned. I still have a bucket of parts from the original front end if anyone is interested.

 

Very clean looking.........

 

Any problems wiring the gauge? I have to wire the same gauge..

 

I should probably do a full write up on it. The main thing I remember without having all my notes is that:

• The manuals reference to "oil" is the fuel sensor. On my bike I just sent that signal to ground since I don't have a fuel gauge.
• The gauge needs a constant 12v battery signal to hold the settings as well as a keyed on 12v signal.
• The gear position wires (1-6) you can ignore. Or use one of them for your low oil light. I chose to use the "position lamp" or running light idicator since it was a little redundant. (I can tell if my head lights are on)
• The tach, since my bike had a mechanical gauge I spliced into the orange wire going to 1 of my coils. I then set the gauge to my bike being a 2 cylinder and compared the readings up to 4K against the stocks gauge with it lining up. (Strange, but it works)

I will note, that the firmware from my version is different than every other version I've seen online in YouTube videos. I don't cycle through 5 pages of settings, they are all displayed in the setup screen. So I'll have to see how I can adjust the wheels speed sensor to give me an accurate speed.

Let me know if you have any specific questions so I can address those in a more detailed write up.

All in all, it's a good speed for the $35 I paid for it.

 

Can you share a copy of the manual ? I have the same gage and had 0 information supplied with mine

Thanks

 

Here's where I bought mine. The last 2 photos are the manual.

https://www.amazon.com/dp/B01J77O0OS/ref=pe_1098610_137716200_cm_rv_eml_rv0_dp

 

G'day Taylo105, a little late in discovering your Seca build... the GSX front end really changes the look and I reckon for the better. I have a stock XJ650RJ that I will start restoring. "Blind" woman backed her car into it. Only damage was broken clutch lever and dent in speedo bucket. Do you still have your chrome gauges?

 

There's another member on here who has spoken for the gauges already. I do still have the clutch lever if you were interested though.

 

Updates? Got an m-unit blue on the way for wifes bike.

 

I've gotten the bike pit back together and have been able to ride it around the block. But I'm working on the ignition system as I'm intermittently getting 3 or 4 cylinders running. The munit was a very wise investment on my part and I'm glad I bought it. I just wish I had wanted for the blue to come out because I want the Bluetooth feature. I've got an updated wiring diagram I did that I will share shortly. Let me know if you run into any issues

 

Very cool. yea I'd love to see the diagram sometime.
Wifes bike is XS400 so the charging sys is bit different etc... But I would like to redo my seca at some point also.

 

Here is my wiring diagram of the m unit with the m button. I highly recommend the 2 of them together as it allows you to have only 2 wires going to your bars, 1 positive and 1 negative wire.

I based this off of the simplied wiring diagram. I removed all of the safety switches on the bike. With the m unit it contains all of the relays needed too.

 

very clean, I like it

 

Build update:

I had to move the bike out of the garage I was in so the last week was focused on moving the bike, cleaning out the old garage and moving it to my apartment. I've turned my extra bedroom into my workshop. So it's a little more difficult to work on the bike. (Run from outside, up the stairs and into the house to grab a wrench, then run back outside only to find I grabbed the wrong one) but atleast I can enjoy air conditioning while working on parts off the bike.

I rebuilt my brake calipers as the original gsxr calipers were destroyed. The seals were rock hard and packed with dirt. Luckily all the pistons in the calipers looked great. I even added a fresh coat of paint to liven them up.


Pulled the carbs and coils off the bike and brought them inside. On the carbs, I missed cleaning the air/fuel mixture screws as the caps were still on them. After removing the caps and inspecting the holes, I could see some gnarly stuff in there. So I will be breaking the rack again and taking them back to church over the weekend. Afterwards the new orings and screws should be delivered from chacal so I can put them back on the bike and tune.

Also the coils were removed and tested. Turns out my primary resistance is a little too high. After a ton of research I bought some cb750 coils. I like the idea of the removable wires if needed in the future. Once these are delivered I should be set. Fingers crossed.

Now the question is, after the carbs come back from church, should I paint them? I've got a freshly painted engine and calipers. I kind of like the color contrast (otherwise everything is black) but I feel like they could be livened up a little.

 

I painted mine black to match my colour scheme and love it. I wanted them to blend as much as I could and have the fender paint pop.

 

Any tips? Specific paint you used? (Everything I've done so far has been rattle can) and any items to take extra care around? (Small passages for example)

 

I'm a rattle can guy too.
For prep I had them broke all apart and used a rubber sage degreaser on a clean rag and wiped all over. I taped around the rubber choke boots as the paint would just look bad on them.
I followed the degreaser with a nice automotive filler primer, seems to bond better. Once that dried I usedba high temp paint. Not for heat but the inclusion of ceramic seems to make it a little thicker and a little tougher.

 

http://www.kgcoatings.com/products/motorcycle-and-automotive/2400-series-gun-kote
this is what i used, it's kind of a p.i.a. to do but there's nothing else like it.

 

Wow very clean! I might have to do this

 

Finally some great news. After spending the last week rebuilding the carbs and taking them to church yet again, re-setting the float levels and installing new cb750 coils, she finally runs. I hooked everything up and she fired right up. Seems to be running a tad rich at the moment. So over the next few days I'll bust out the carbine and the colortune to dial her in.

I just have to say a HUGE thank you to everyone for their help with getting her running. I will admit at times I thought I had gotten a little over my head, but with everyones help and feedback on the forum she's back.

I will be finishing up the build page with some detailed recaps of what was done, and once I get the speedo configured a write-up on that as well. And finally, some awesome shots of the bike to share with everyone.

 

Absolute pleasure reading this thread. Thank you for responding to mine. I am much more stoked now about this build. Downfall is I believe I'll be needing a lot more $ than I previously expected. Haha. Still will be much less expensive than my Harley

 

Having some issues, I'm terrible with wiring... I've figured most of it out, but having problems with how the start solenoid should be wired up with start button etc. Any pics / explanation of what you've done?

 

So a build update since its been awhile. I've been working to get the bike tuned (details in a different post in the technical page). But i'm moving closer and closer which is great.

I took the bike out for a quick ride today around my neighborhood. Had a cyclist ask me if it was a cb750. haha. Once the carbs are fully tuned its time to finish the speedo setup. I need to build a mount for the speed sensor and then play trial and error to calibrate the speed. Shouldn't be too hard though since I'll compare it to a GPS speedo to get a difference.

Once everything completed, I'm putting together a nice shoot along the coastline with a little video reel too. Can't wait until i can share those with everyone.

 

Dialed in the carbs a little more this weekend. Was able to take the bike around for a few mile ride this time. Feels nice to actually get the bike up and moving. Still need to do some additional adjustments. And I found the cause of my tiny oil leak. I hadn't replaced the crush washer for the oil drain plug for the last 2 oil changes and it's finally giving out. So I've placed an order with chacal for a set so I don't run into that issue again.

I also built a mount for my speedo and the speed sensor. Will snap some better photos after work. Now I just need a cellphone mount so I can compare the speeds to properly calibrate it.

 

Get a RAM mount.

 

That's exactly what I want. I need to measure my stem to see if I can get the stem mount version or see if I'll have to use the bar one

 

if you just measure the tire the speedo will be right

 

If your speedo works with a magnet on the wheel or brake disc, the best way to get the precise circumference of your front wheel is to put a dollop of mustard on the front tire. Roll the bike through 2 complete rotations of the front tire on your driveway. Measure the distance of the 3 mustard spots and divide by 2. The more rotations you use the more precise your measurement will be. Mustard is much more visible than ketchup

 

Unfortunately my speedo has some issues with the circumference. I have an older version of the universal gauge which is adjusted by a ratio vs a circumference, Hence why I'm going to calibrate it against a gps speedo. Plus this will also allow me to verify the speed is accurate through my speed range.

 

What kind of forks did you swap over? and I see that there are different wheels on the front end. This is coming along very well. I have an xj650 of my own and need to either do a fork swap or lower them some how. Oh and what kind of speedometer did you purchase?

Thank You and good work!!

 

It's a 2002 gsxr front end swap with a custom triple tree to make the swap easy. If you're interested, I have the original front end of the seca with dual disc breaks if you wanted more breaking power. That would be the easiest fork swap vs doing a full on front end swap.

For the speedo, I went with one of the $35 universal speedo on Amazon. A few other members here have used them with success.

 

Oh wow! I want to do the fork swap but I am unsure as to how to get the triple tree to swap over and match to the XJ

And thanks I'll have to checkout the speedo!

 

The easiest way (and most expensive) is to have a new triple tree made. Cognito makes custom ones for gsxr front end swaps as it's a very common front end donor. However you can always use the existing triple tree from your donor from end, and have a new stem made. Usually you will run into issues with the length size. This is a much cheaper route. There are a bunch of companies that offer those services online. However cognito is the only 1 I've dealt with.

 

An

I have another question, would it be possible to keep the old wheel from the xj onto the new forks? Maybe using spacers?

 

the speedo hub is part of the spacers and "locks" into the lower fork. but yes if your new forks are wider spacers will be the way to go. just remember it will have to center the wheel on the forks and still lock the speedo hub

 

Okay thank you!!! Would the GSXR brake calipers work for the old wheels?( last question I promise haha)

 

Possibly, but not easily. The rotor sizes are different so you'd have to machine new brackets to move the calipers. If you're trying to keep the xj wheel, I'd say you should keep the xj calipers on it. Since you want calipers and rotors that work together.

 

So I finally finished 1 detour that I came across. Turns out the original stem which was made with my custom triple tree setup was about 1/4 too short which caused a number of problems to occur. After reaching back out to the guys there, they corrected the problem and sent me the stem back. I got the stem and triple tree setup this afternoon after work and took the bike out for a quick lap around the block. She still has her idling issues. So hopefully 1 day after work this week I can tune her since I'll be out of town this weekend. Hoping I can get around to finishing up everything to enjoy some riding. Luckily southern California has almost year around riding season.

Pic for fun


Nothing like working on your bike in your uncovered apartment parking spot -___-

 

The neighbors must love you!

 

Luckily no ones complained about me. My neighbor has an old Harley that he loves to ride late at night. That thing is loud!

 

So I know I have been lacking on this lately, but life has gotten in the way. After a short ride this weekend to calibrate the speedo, I’m spending the evening after work trying to tune. She runs a little lean, so I’ll be pulling the plugs and inspecting, and hooking up the colortune and carbtune. Hopefully after that she will be ready.

 

So after hooking up the color tune after a quick few laps around the block, all of the cylinders had the same blue tint flame I snapped some photos of the plugs. These maybe have 20 miles on them. I adjusted the enrichment circuit screws to richen up the mixture a tad. I adjusted the screws about 1/8th of a turn at most and the bike felt better. Had a quicker throttle response, and a less frequent hanging idle. I do occasionally still have a hanging idle that is resolved by simply letting out the clutch to pull the idle down.

The issue I'm still having is the idle does not quick fall down. Its mainly noticed when shifting. Even if I roll off the throttle, wait a second and pull the clutch, the rpm's will increase for that moment. My thought is to richen up the mixture a tad more and see if I continue to see improvements.

Pic's of the plugs.

Plug 1


Plug 2


Plug 3


Plug 4

 

Yeah... A bit lean

 

maybe a bit lean but 20 miles isn't enough. check them again at 200 miles

 

Those deposits look like the beginnings of the accumulation of oil burning. Have you ever done a compression check on the motor? Are there any signs of a bluish gray smoke from the exhaust?

Picture 4 is a bit blurry, but that looks to be a BP8ES. I believe the stock plug (slightly hotter) is the BP7ES.

Per Len:

"XJ650 engines:

HCP1292 Original BP7ES NGK SPARK PLUG, stock non-resistive plug is correct for all XJ650 (except Turbo) models."

How about slight popping during engine deceleration either by blipping the throttle or by engine braking? If the engine speed increases during shifting, you definitely have a problem; either a vacuum leak or a tuning issue. I would consider being a bit more aggressive on the idle enrichment adjustment screws if my confidence levels were high on the carbs and intake manifolds.