XJ650RJ Seca Build

So i'm finally getting around to creating my own build thread. I'm currently in the middle / early stages of this, but want to be able to document my process for myself as well as other members of this site.

This is my second XJ650 in the last year. I picked up an 81 Maxim and had it for a few months before the neighbors destroyed in -__-

after that unfortunate loss, I kept my eyes peeled for a Seca. Eventually finding one in town.


The previous owner had done a few minor "upgrades" to it.
- Clubman bars
- Wrapped pipes
- Pods -____-

After riding it for a little while, I decided to switch back to the stock airbox to resolve the high idle since the PO did not reject the carbs after putting Pods on the bike. This helped, but there were still some running issues. After completely re cleaning the carbs, breaking the rack, replacing all seals and a few jets which had seen better days the bike got even better.


Then, I got a wild idea to build the brat style bike I had wanted.....

 

If you bratted your Seca 650, then I suggest not posting the carnage here. That is among the most collectable of XJ models in the U.S.. Available for one-year-only here, and highy desireable.

If' it's the Maxim that you bobbed (and you should have since the damage shown is all easily reparable), then post away

 

After realizing that my uncovered parking spot at my apartment was not the best spot to attempt a build project, I was able to convinced the girlfriend's parents to lend me their garage for a few months while I worked on the bike. After getting it there, I got a corner of the garage setup as my station. Not a bad little setup for me. Here's the photo on day 1..


Here's the photo after 2 days of tear-down.


Everything has been carefully removed, labeled, and inventoried to help ensure that when its time to re-assemble, everything goes back as it should.... Don't want to worry in the back of my mind where those extra few bolts went.

Checklist of items still to complete before the re-assembly are:
1. Powder coating frame after minor fab work (seat hoop installed. Yes, I cut a Seca frame.)
2. Powder coating the rims to revive them, since they are older than I am.
3. Cleaning the engine before a nice coat of paint.
4. Stripping and repainting the tank.
5. Waiting on the post man to deliver a few more parts so everything is together before it goes back.

 

OK, SO-------you're hating on yourneighbors cuz they destroyed a 650 Maxim.........the you turn around and tell us that YOU are destroying a 650rj!?! Lol

I'd very interested in the seat if you're gonna ditch it, and the mufflers, too--And the tank

Dave F

 

Destroying is a strong word. Haha I know to a purist making any modification is scary. But the rear chop is minor. I'm only flattening the rear to keep the lines as they are and then building a nice seat to mount on top. I want to keep the pipes on it as I don't want to adjust anything with the engine. I restored the bike from having pods to go back to the air box for reliability.

But yah, the seat should be available. I'll snap some good photos for you to check out.

 

If you could, send them to me via cell phone... I can see them any time.....I'll give that to you in a private message

Dave

 

When a bike is collectible any change dramatically lowers the value. This isn't about being a purist; it's about having respect for what the machine is. I'm not sure what you paid for it, but restored examples are fetching between $4,000 and $5,000. While that doesn't seem like a lot, the same bike in the same condition was selling for less than $1500 about five years ago. You could have restored it, sold it, and financed half a dozen other builds (or taken a really nice vacaction).

Having said that: it's your bike to do with what you will. Take your time. Be precise with your work. I'm sure you'll have a fine looking machine once you're done.

 

but when Taylo105 is known as one of the most respected bike builders on the west coast, this will be one of his early works. easily fetching 20K+

 

Could be. I know a guy in Oregon who started out building bikes from parts who now does well over $2million a year in business at his shop. That takes a serious amount of dedication to both the trades and to business though.

 

The Seca would look great restored to original spec.

 

The 650RJ already has the look of a factory cafe racer.

 

Let me know about any 650rj stock parts you don't want hanging around and we can work something out.

 

Stock part list for sale. The next post will include photos

• Front fender. No dents or anything, but most likely will need some painting
• Rear fender with lights, tool pouch. (Brake light wires were cut)
• Front brake rotors.
• Front brake calipers
• Stainless steel brake lines (purchased from xj4ever)
• Stock gauge cluster. (Oil and high beam light have a crack)
• Stock levers. Wires are still intact
• Stock controls. Wires are still intact
• Aftermarket clubs. Installed by PO, and I personally am not a fan.
• All 4 turn signals. Wires are still intact
• Stock wiring harness. With original fuse block. (Needs to be replaced). Only wires which are cut are the brake lights.
• Triple tree. (Only top is pictured but full set is available)
• Front wheel
• Forks

I have all of the necessary bolts, nuts, and hardware for all above items and they will be included.

 

http://imgur.com/a/iEanv

 

Here's some updated photos of the build. Got the frame back from powder coating and got the new custom triple tree setup with the donor front end.


With the new brat seat pan mocked up. Now to get the new seat upholstered.

 

And the engine which is waiting to go back into the frame.

 

where did you get the hoop?

 

eBay for the win.

http://m.ebay.com/itm/CAFE-RACER-TR...ASAKI-230mm-/182272192219?txnId=1624927223008

 

Got the frame back from powdercoating and finally got the engine and swing arm attached.

I honestly don't think that the "chop" I did was too extensive. I know some will hate it, but o think it creates a nicer line and flow to the bike.

Still waiting on the new rubber to be put on. Waiting on a new tire valve stem from charcal. And having the fork seals replaced for the new front end. I didn't want to tackle that and found a shop that had a fair deal on the labor.

It should be a roller once again by next weekend. And then it's time to tackle the electronics with the motogadget munit.

 

Hello, do you an updated list of what parts are available for sale?...interested in both controls and possibly gauges/cluster


Thanks


Frank

 

Lookin' good!

 

Updated parts list

• Front fender. No dents or anything, but most likely will need some painting
• Rear fender with lights, tool pouch. (Brake light wires were cut)
• Front brake rotors.
• Front brake calipers
• Stainless steel brake lines (purchased from xj4ever)
• Stock levers. Wires are still intact
• Stock controls. Wires are still intact
• Aftermarket clubs. Installed by PO, and I personally am not a fan.
• All 4 turn signals. Wires are still intact
• Triple tree. (Only top is pictured but full set is available)
• Front wheel
• Speedo sensor

http://imgur.com/a/iEanv

 

She's almost a roller again. Should be picking up the rear wheel today and getting it reinstalled this weekend.

 

good find I need a hoop for the tail that the PO cut off an xj750 looks like it will fit inches check out.

 

Do you still have the rear of the frame that you chopped off?

I just picked up a free Seca - I'm told it's a 650 but I can't verify that yet. If it is, I would like to restore it to stock condition but the PO "bobbed" the frame. I would actually be interested in a bunch of the parts you have if this does indeed turn out to be a 650.

 

what is that front wheel from?

 

It's off of a gsxr. Did a front end conversion with a custom triple tree

 

So this took awhile, but I finally have a new brat seat for my build. I looked at options to buy one pre-made, but wanted the satisfaction of doing it myself. While this is not 100% perfect, I'm happy with it knowing that i made this.

Started with a cardboard template of the size of the area I needed.


Then bought some steel to create my seat pan. (ignore the foam attached at this point. I realized, I didn't have a photo of just the seat pan)


Then I attached the foam. I got some free samples of some foam from and was able to pick out the density and thickness I wanted


Here are a few of my attempts with the seat. From left to right, First "hack" job at the seat. Middle is my first real attempt to create the top of the seat. I realized that I wasn't overly satisfied with the seat and started another one. Right is the final seat top which I did and was happy with. I sprayed adhesive on all of the layers to help hold them in place. Then created my "boarder" stitch to re-inforce everything while I did my pleated stitches before finally cutting the top to shape from my original template. While being sure to leave a little extra room around for my stitching.


My final product. After stitching the sides on, I used rivets to hold the seat in place. The original bike I had years ago (in my first post of this thread) was just attached through spray adhesive and was starting to fall apart. So I opted for a more secure method.


I should have the seat on the bike this weekend, when I head back to finish up the build.

All that is left to do is finish cleaning and assembling the carbs, and then redoing the electronically which shouldn't be a problem since I have a motogadge m-unit ready to go.

 

Love it so far.

 

Outstanding!
You need some hi tech shocks on the rear, to complement for the front end!!!

 

Yah the rears need to go. So I'm adding extra money into the budget for the build. Currently looking at some progressive shocks as they come highly rated. Unless I can find something better without completely breaking the bank.

 

Finally got the seat actually attached to the bike and I'm very pleased with it. Still rebuilding the carbs. Had a few items come up this weekend that prevented me from working on the bike. Got hung over after a wedding, and then had to do the brakes on the girlfriends car. So progress is slower than expected. But still moving forward.



Hoping to have the carbs assembled and back on the bike next weekend.

 

I removed the springs on my shocks and painted them black, gives it a nice look for now until you can get the progressive ones.
whats your plan on the exhaust?

 

I'm probably gonna pick up a new set of shocks here in a week. And for the exhaust I've still got the original one which is in great shape. Did a little bit of sanding to buff out the light surface rust. Later on down the road I may swap out the exhaust though.

 

Pipes are in decent shape. (Obviously an old photo as the forks are now on the bike)

 

front end from gsxr 600/750? where's the custom triple from?

 

Yep. 01 750. I got the triple tree from cognito moto. They can build triple trees for any front end swap combination. There's other companies available for slightly cheaper, but I loved how the cognito moto triples looked. Just mail in your lower and stem, and pick your style you want.

 

very cool... sounds pricey... ha

 

More than I would have liked to have ideally spend, but you get what you pay for. I knew this build was going to be expensive ahead of time so atleast I braced myself for it. And I'm not taking shortcuts along the way and am getting exactly the bike that I want. Still way cheaper than a new bike, and this has character to it.

 

absolutely agree... hah contemplating doing something similar now with my seca.

 

Do it! I love seeing builds from other people. The only thing I wish I had done was film the process to have a better archieve of the process. I guess I'll do that on the next bike.

 

Very cool. Ideas on what you're going with for rear shocks?

 

I'm thinking the heavy duty progressive shocks for the rear. I'm thinking I'll finish up the rest of the build and make sure everything else is working perfectly then grab a new seat of shocks. I can ride solo on the original shocks for now.
I'll definitely be doing a round 2 on this build in the future. I want to eventually reprint the tank, and change out the rear sets. And possibly upgrade the munit to the new munit blue.

 

Did progressives on the wife's bike. Made a world of difference.

 

I can't wait to see how it turns out. I've been searching for a 650 Seca for months now, so my gut kinda clenched up when you said you cut it, but it looks pretty cool so far. I can't wait to see how it turns out.

 

Got a box of parts delivered last night with my new brake lines. So I'm hoping to get those installed tonight. Then all that will be left is rewiring the bike and final tuning.... unless anything else comes up during the final hour....

 

Very interested in the M-unit.

 

It's awesome. I only wish I had waited to buy it until now because they came out with the motogadget blue which has Bluetooth so allows you to use your phone as a key. I'll def post info on my setup and a wiring diagram of my setup too

 

Got the brakes installed yesterday and did a mock fitting of mostly everything on the bike(missing exhaust). This will help give me that final motivation to finish everything up.
Now the rest of the weekend is all about wiring. I've got my work station setup with all the wire I need, and multiple wiring diagrams.

 

What are you planning to use for switches? Stock or the motogadget stuff?