YamaGPZ 650 Project

Front wheel was good since I'm using the matching YZF forks and steering stem. Rear divvy wheel looks like it's tracking straight but I'll have to check soon. If not I'll have to trim the cush drive side a bit.

I noticed you have a couple of nice exhausts, which do you like better, the Vance and Hines or Marshall?

 

How much was your tail section if you don't mind me asking and where did you purchase it form?

Thanks

 

It's the 'HAMMER2' seat from airtech. They have a list of updated prices on their website at the very bottom: http://www.airtech-streamlining.com/vin ... ts_box.htm

Pretty good quality stuff, I was able to cut my down with ease. They were also super helpful on the phone with any questions. I do remember them having to make the section before they sent it though! And shipping was a bit of $$$!

 

Cool, thank

 

Looks great, look forward to updates with pics and descriptions.

 

Nice work... Shaping up nicely

 

Had the Marshall just over a year and to be honest its crap. First thing was the chrome started to chip of before it even went on the bike, got even worst when fitted.
Had to be painted black because of the flaky chrome it’s a very cheap system, the baffle is non removable but started coming loose and is slowly blowing its way out of the muffler.
The Vance and Hines is pretty good so far came on the bike when I got it but in next to new shape. Removable baffle with one 10mm bolt the whole muffler is removable, you will have to remove the muffler to take the back wheel out but that’s just held on with the rear foot peg. Sounds good nice and deep and has a good quality of chrome (very hard), also is a full performance system.
So I would say Vance and Hines I have yet to use it on the road but good so far. When the Marshall finally gives in I will be looking at replacing it with one of these. http://www.wemoto.com/bikes/Yamaha/XJ_7 ... _-_Chrome/

Can get you some pictures of both pipes is you want, hope this helps.
Al

 

Thanks for the info! I'll def stay away from the Marshall then.

That marving exhaust looks great! I'll have to figure out how much it will cost for me to get one into Canada and see if it's worth it. There doesn't seem to be much info on them the web; but, the info that exists makes them sound reputable.

 

Contact Marvin through their website, you never know they may have Canadian or U.S distributors. Worth an email!

 

I think they may do as they are quit new in the UK, only been on the scene a few months. looks to be a nice pipe sounds good to, keep it up.
Al

 

Ok started to tear into the top end of the engine. I'm not going to split the cases but since I was having lots of trouble with dirt and debris near the bores I figured it was worth cleaning out the 20+ years of crap and seeing if everything checked out.

Cylinder head with valve buckets removed. Next step is to take all the carbon off the valves and clean everything up. Might grind the valves in but I have no idea if it's necessary right now.



Here's the cylinder block removed as well as the pistons. You can see a lot of the grime I'm talking about.



Follow the advice of the Haynes Manual and do not take off the cylinder block straight up. You will get so much crap into your cases that you might have to tear that down too. You can see the accumulation of debris here on the rod, and this is just 20% of the dirt that was there. I think it's an accumulation of dirt and the plastic tubing they put around the studs that have since worn down.



Started to clean up the pistons. I'm using simple green and here are the results. One thing I've noticed is how pitted the tops of the pistons appear to be. This was a bit of a shock considered I'm used to seeing machined or completely smooth piston crowns.





Note that even the Haynes manual says to use a metal polish but I can't begin to imagine how I would smooth that kind of pitting out without doing serious damage.



But it looks like the picture has the pitting too so no harm done? Is the rough surface standard for XJ motors? :?:



Checking the rings for clearance: I seem to be ok with the top ring giving me an average gap of 0.60mm which is not within new spec but definitely not at 1.00 mm yet. The second ring gives me an average of 0.30mm which is definitely fine. The bores look alright too so I'll probably just drop the old rings back into their respective bores.



If you ever remove rings don't do it like the manual says, get a piston ring remover/installer for $5 and never look back!!

 

Yea I'll give them a shout, def worth a shot! Was hoping to find more info on them but looks like I'll have to be the guinea pig if I get them.

Yea I looked at their site looks like they do a lot of ATV work so maybe I can find more info there. Found a picture of one of their pipes that sure makes them look nice! Mind you I don't think they have this 'blackened' version for us.

 

I am afraid a cannot help you with your pistons as I have only ever pulled 2stroke pistons, but it all depends on your budget and weather you what to tune the motor or not. As for the pipe they offer it in chrome and black steel so you could always paint the black steel version, I am not sure weather they can make you one in stainless heard they can but no idea if it’s true.
Al

 

So decided while I had the engine apart I would put new rings in for the experience.

New rings ready for freshly honed cylinders; I had three sets of rings on hand and got one shipped from Chacal, great service as usual!



Just getting ready to install... We did end up switching the 2,3 to TDC as it was much easier to manage.



Had a custom bushing made up for the rear caliper mount. It's press fit into the bracket and glides perfectly over the stock rear axle. Just have to work out the details now - probably going to have to shave some metal off the cush drive in the new rear wheel for proper alignment.



On that note does anyone know the best way to measure and centre the rear wheel? Does the XJ normally have any offset like Harleys or is it centered between the frame rails?

 

Quick little update where I'll let a grainy spy shot do the talking. Hopefully you guys like it!

 

Shes coming on nice!
Al

 

Any chance of shooting a photo of the rear set mounts? Mounting a R1 rear set on my build, figure I'll be welding some plate and bungs on, curious how yours mounted up.

Cheers

 

I'll grab a picture for you. I used mounting plates attached to the frame mounts and right now they are just fabricated out of some thinner aluminum to see how they sit. The problem is that I've found that they are too far back and the foot position is uncomfortable.

I was looking at the site "Cycle Ergo" which shows the position of rear sets - looking at the xjr1300 gives a pretty good comparison of placement.

Anyway, hopefully it can help you position yours b/c I've found it's no easy matter!

 

Here is a picture of the rear-set mockup. As I said before it is quite far back and is uncomfortable for me to use due to the angle.

 

Yup pretty much what I had pictured. Thank for the pict.