Dean's XJ650 Cafe Project

After thinking about it for a long time, here we go! These are the "before" pictures.






Note the "professional" way the shop fixed the fuse box problem for the PO!

Wish me luck!
Dean

 

Good luck n have fun doin' the build. 8)

 

Hey, that's what my electrical looks like... It's OK because it works correct now on my bike.

 

Good luck with the project!

 

Today I did some tearing down...had to stop when a storm came through. Hope the child labor people don't object to my helpers!

 

She looks handier with the wrenches than I am!

 

Ok, today's update. I've replaced the coils, turn signals, tach, handlebars and switch gear. Working on the speedo and the rat's nest in the headlight bucket.

New rear turn signals


New signals from the side


Comparing old and new signals


The new view from the seat


Dean

 

Dean on ur tach. It looks like u got it from Mikesxs!?! Anyway how many wires does it have? The 1 I bought had 2. So I sent it back. Thinking It wouldn't work. Since I'm told I have 3 wires 4 my stock tach..

KAOS

 

KAOS,

Yes, the tach (and speedo) is (are) from Mike'sXS. It has two wires, but so did my stock tach. I don't have the battery in the bike so I haven't checked that the thing works yet. I know I'll have some troubleshooting to do when I get the battery hooked back up.

Dean

 

holy rusty carb tops batman!!! Nice signal lights!!!...be sure to wire them with a trailer harness so you don't need a brakelight too...clean is the only way to go.

 

Yes, dwcopple, this bike has seen some weather! I've been looking for replacement hats but they're harder to find than an honest politician!

 

I like what your are doing with your bike! Got a question about the turn signals. What type, and where did you pick them up at?

 

Thanks, VET!

I got the lights from Dennis Kirk.

Turn Signals

They're incandescent, dual filament. I like their clean, small look.

Dean

 

Yeah thats exactly what I saw in them. I'm thinking about stealin your idea for my bike. Thanks for the response.
Ken

 

not to hijack thread but ;-)

dwcopple: what you mean trailer harness?

 

Today's update. New shocks, wired up speedo and left hand switches, carbectomy, mirror, and some polishing.



New shocks from the back


Updated view from the seat


Headlight bucket salad


Carbs.....do I win an award for the grungiest?




New mirror

 

like the shocks; where'd you get them?

 

Hi ddibling, the shocks are great, I realy like the indicators too, what is the story with them, the lenses look red, is that the photo? I would love to give the old indicators, wit h their long stalks, the flick.

 

Got the shocks from Chacal, where else? :^)

 

Dean,nice work thus far! I think wizard wanted to know where you got your turn signals from. And if he didn't,I do. They look awesome!

 

Hey! Thanks! I got the turn signals Dennis Kirk. Turn signals

They have incandescent bulbs and came with both red and amber lenses so you can make them whichever you like. I put amber for the front signals and red for the back.

Dean

 

This gives me some really great ideas, and I was looking at some turn signals kind of like those, so its great seeing them in use

 

KEEP UP THE GOOD WORK DEAN!! KEEP US UPDATED, PLEASE.
(DID YOU GUYS START A NEW THREAD ON THE HARNESS?)

 

That thing looks like it's coming along awesome, but what was meant when they said trailer harness for the lights to work right? I'm curious.

 

One more question, in three parts. What kind of bars, where did they come from, would you have been able to keep using the stock guages with them? Thanks.

 

A trailer harness adapter is a small black box that allows a 4 wire trailer to work with a car/truck with amber turn signals and separate brake lights. Otherwise trailers would require 6 wires and more lights.

You can't just dig it out of a car easily because it's buried in the column ( on GM's) and it also makes the 4 ways work. So they sell one for around $40.

 

Keep it up! Love the pictures, I'm thinking of doing the same on my 550. I hope everything is working out for you!

 

ya cant wait to see what some honest elbow grease looks like on those carbs man, unless you gonna buy a new set, but keep up the good work.

 

New seat came in today. I just sat it on the frame to see how it looks. Now to figure out how to mount it.....





Cheers!
Dean

 

where did this seat come from?

 

I got the seat from Airtech. They also make an upholstery pan to match, which I need to get, too. That way the upholstery will look very professional...nice and clean. The seat is actually for an old BMW, but it fits the frame just about perfectly.

Dean

 

Are those shocks shorter then the stock ones? If so how much did they drop the rear end?

 

I believe they are the same length as stock. I swapped them one at a time and I didn't have to do any pushing or pulling...

Dean

 

damn I was hoping they were shorter.

 

I'm sure you could get some shorter if you want. I got those from Chacal, our resident part guy. I have seen that same shock in a "mix-and-match" form. You bought the piston part at whatever length, then buy the springs to match.

Dean

 

Great work I can't wait to see what it looks like when it's done This is what i wanted to do when i bought mine but I decided to clean it up and leave it stock (i'm still not sure if it's going to be less work!)

 

Whatever happened to this project? I was diggin it a lot.

 

Actually, the project is still underweigh, just got bogged down. I'm working on my doctorate, work is crazy, and I started taking the carbs apart...they're gunked up solid. Also I've been waiting for almost a year now for a new tank from the Tank Shop in Scotland. It will be worth the wait but, jeez!

 

ooh, what Tank Shop in Scotland? I'm in Scotland and my tank is looking way past its best..

Got a link or a pic, details!! details man!! lol..

project is looking good so far

 

The Tank Shop

They're making me a 5 gallon Manx-style tank. I cut the bottom of my old tank off and mailed it to them so it should be a drop-on install when it's done. Hey, if you're in Scotland maybe you can drop by there and see how my tank is coming?!?!

 

Ah, sounds interesting! Would love to see how it turns out & fits - Hopefully you'll get it soon, it's been a long wait!!

You know, I would pop in but I don't live that close.. would like to see some of their tanks in the flesh mind you.. they're quite a price.

 

dean, that is gonna be one sweet bike when you finish it! Do you have more photos of the seat? Did you figure out how to mount it etc, any tips that you could share? I am looking into a similar seat and just wanted some visualization to inspire me and make things easier for when I order mine.

 

Thanks, xulf13! I haven't mounted the seat yet. I'm waiting on the tank so I can visually line them up...I want the bike to look "straight." That's one of my few complaints about the xj...it looks "bent"! Anyway, I'll put some new pics up soon.

Thanks,
Dean

 

OK, maybe I'm inpatient, but I want to see more.
Two question regarding your new gauges.

on the speedometer, did or does the stock cable fit and screw into the back just fine?

On the tachometer, What did you hook your two wires up to? and do the gauges have night lights in them? meaning a bulb in the back?

I am about to order my seat and I am in need of some smaller or round gauges, but like KAOS had mentioned, my stock tach also works off of 3 wires instead of two. But I know it is not about what my stock tach works off of but what the new tach will need. Unless the only way to get a signal onto the tach is via three wires, which I doubt, I just think my stock tach needs three.

Anyhow, more pics would be nice so we can all drool.

I was looking for the manx style tank that you will have on your bike and all I can say is that it is going to be one sweet bike when finished, wait I already said that. Well, x2 is never too much

 

What a dope I am. I just realized you have an 81, meaning, your tach is cable driven, therefore the need for only two wires for lights only.

I think I am gonna get the electronic tach (03-675) from mikesxs but it will be a bit smaller than the speedo and only comes in black.

 

Coming along great man.

 

Thanks, Ease! I take that as high praise coming from you. Looking at your bike was a big inspiration to me.

Dean

 

Did you ever find some way to get those caps tidy? I found this (copier) toner cleaner that killed the rust and then I polished them up with a metal polishing kit. They look waaaay better now. You have me inspired to go all the way with mine. I love the cafe look but wasn't sure if how to convert the seat on my Maxim. And the tank idea was genius. I bought an XS400 tank only to find out it wouldn't drop down fully on the frame. You have to finish this project. Good luck on your doctorate.

http://www.enkaypolishing.com/aluminumm ... ngkit.aspx

 

Ok, I finally got some stuff done today. Minor stuff, really, but something is better than nothing, right?



This is my solution to moving the electronics out of the way. I need to find some black cable ties...the white one's look a little out of place against the frame.



Got the exhaust can and brake pedal back on.



Got the seat painted and have the seat pan and upholstery ready to put on.



Got a question for the group. Can I remove this bracket (see the yellow arrow) without causing problems? I need to mount my gel battery under the seat and this bracket is in the way. I want to remove it and then put a sheet metal shelf to mount the battery on. Any comments/ideas?

Thanks!
Dean

 

Hey Dean. You can cut that out without anyt problems. I did on mine and others who have bobbed their bikes do as well. It wont husrt the structure of the frame since it's behind the shocks anyways. Your bike is looking good by the way. Keep up the good work. Any news on that tank?