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My 82 XJ650 Maxim Complete Rebuild

Discussion in 'XJ Technical Chat' started by jayrodoh, Jun 19, 2016.

  1. jayrodoh

    jayrodoh YimYam Premium Member

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    I had another thread started but it got out of date and a little off topic, figured I would start a new one now that it is done.

    Huge thanks to all the countless members that assisted through the project with knowledge or parts, I would not have ended up with a bike this nice without it.

    Here she is when I picked up. Happened to be in my home town for a weekend project and stopped in to see some old friends. We used to ride together about 15 years ago and this was his ride then. He had picked up a Heritage Softail since then and the XJ became a patio ornament. At least it was covered but she was rough and not running. A couple beers and $200 later it was in my truck.

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    Fast forward 19 months, here it is! Ignore the goofy mirror, Chacal has a couple sets on the way to figure out what works with these bars. The last set had me looking at my shoulders.

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  2. jayrodoh

    jayrodoh YimYam Premium Member

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    Bike was a total teardown. Major issues were 5 broken intake/exhaust studs, oil leaks, and a couple splits in the frame from frozen water. Frame was powder coated once repaired.

    Frame:

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  3. jayrodoh

    jayrodoh YimYam Premium Member

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    I tore the engine down part way, it had good compression numbers so I didn't see any reason to tear it down past the head. Every gasket and seal that I could access was replaced. Since the original head had 5 broken studs, I opted for a good replacement which I then tore down and rebuilt completely.

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  4. jayrodoh

    jayrodoh YimYam Premium Member

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    Cosmetics. PPG paint, I can't recall the color. All the little pieces were powder coated. Once I struck up a relationship with the shop, it was about $6 to blast and powder coat all the parts. At that price, it's not worth my time to clean up and spray paint it. One note, if you have your controls powder coated make sure they don't coat the inside. It looks nice but makes it really hard to get the turn signal switch to function properly.

    I picked up a buffer and supplies for under $40 at Harbor Freight and polished the aluminum bits. It's messy work to remove the clear coat but the results were great!

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  5. jayrodoh

    jayrodoh YimYam Premium Member

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    Carbs by Hogfiddles! I've done carbs but I really dislike it as I always get something wrong or get impatient and screw it up. Dave took really good care of these. When startup time came, I just had to set the levels and fine tune. Nice! Carbs1.jpg

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    Attached Files:

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  6. jayrodoh

    jayrodoh YimYam Premium Member

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    And a million other little detail things. Here are the gauges after resto. Don't worry, the rusty bolts were replaced.

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  7. jayrodoh

    jayrodoh YimYam Premium Member

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    Once again I have to thank the members on here!! There are too many to list but some notable mentions go to Len for his amazing parts availability and catalog, Hogfiddles for the carb service and advice, k-moe for the never ending knowledge, sybe for the generous donation of the tach, the list goes on!

    All said and done, here was the list:

    • New brakes front/rear
    • Caliper and MC rebuild
    • New SS brake lines
    • Carbs rebuilt
    • Tapered steering bearings
    • New wheel bearings
    • New swingarm bearings and races
    • New seals everywhere
    • Handlebar swap to Daytona Cruiser bars
    • Paint/Powdercoat
    • New Tires
    • Rebuilt petcock
    • Upgraded fuse block
    • Every other little mechanism I can't think of rebuilt/greased etc.
    • New intake manifolds and airbox boots.
    I still have a couple little cosmetic things like repainting Yamaha on the side covers, but that can wait until winter. I want to ride! Need to find a nice set of crash bars too.
     
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  8. waldreps

    waldreps Active Member

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    Nice bike... I would like to find some crash bars too.
     
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  9. jayrodoh

    jayrodoh YimYam Premium Member

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    Thanks!

    Once more pic since it is fathers day, I had help from my middle boy. He loves motorcycles and riding with dad.

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  10. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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  11. patmac6075

    patmac6075 Active Member

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    Job well done!
    I, for one, have been impressed!
     
  12. bmarzka

    bmarzka Active Member

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    Nice job. And I see you have helpers. Always important to start them young.
     
  13. wingnut325

    wingnut325 Member

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    Nice work! Happy Father's Day!
     
  14. Lightcs1776

    Lightcs1776 Active Member

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    Beautiful results. All the work clearly paid off for you.
     
  15. jayrodoh

    jayrodoh YimYam Premium Member

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    Thanks all! It's a blast to ride, she won't be a garage queen for sure.
     
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  16. smoke

    smoke sleepin' on the job

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    Stunning. Great Job!
     
  17. dirty

    dirty New Member

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    I have just found this website and its great to see these old ( real ) bikes being restored . Im in the process of doing the same to mine .
     
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  18. DrewUth

    DrewUth Active Member

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    Fantastic work, looks beautiful. British racing green? Oh, and forgive me if it is too personal, but I am curious what your total investment ($$) is now that the bike is in arguably better than new condition?
     
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  19. jayrodoh

    jayrodoh YimYam Premium Member

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    Honestly not sure on the color, I'll email the shop that did it as I probably should know that.

    I did track spend, mainly for insurance reasons. I'll shoot you a PM with those details.
     
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  20. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I'm not sure if you are aware, but Chacal carries replacement decals for the ignition and switchgear.
     
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