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PROJECT 900

Discussion in 'XJ Technical Chat' started by wizard, Jun 10, 2009.

  1. wizard

    wizard Active Member

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    I was blaming the oil leak on a dodgy 'O' ring on the oil sender, but it wasn't that easy. :cry:
     
  2. Breaker19

    Breaker19 Member

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    OK, thanks. Looks nice.
     
  3. wizard

    wizard Active Member

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    I put together a tool kit for the bike from odments, for a bit over AU$20,
    8 through 14mm wrenches, with a small adjustable to back up those sizes, a rachet screwdriver with 5 bits & a 21mm box wrench for the plugs.
    What else do you think is essential?
     
  4. Hillsy

    Hillsy Member

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    You forgot the zipties and electrical tape.... :lol:
     
  5. wizard

    wizard Active Member

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    You're getting flash, Hillsy, it used to be bailing twine. 8O
     
  6. Hillsy

    Hillsy Member

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    Well, you gotta move with the times.... :wink:
     
  7. rpgoerlich

    rpgoerlich Member

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    Not sure what holds your side covers on, but maybe a hex(allen) wrench.
    Also a couple cotter pins for axels, unless your still carrying around that spool of bailing wire :D .

    Where'd all your pics go?
     
  8. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    I like to add a small pair of pliers; some Yamaha kits came with them but they were bad news. Picked up a couple sets of decent ones for about $3 on sale.
     
  9. schooter

    schooter Active Member

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    ya, maybe one of those pocket knife style set of metric allen wrenches.., pliers, hrm I bought a motorcycle tool kit, thinking it was small enough to fit in my fork bag or use as a fork bag, but it was meant for harley'swith bags
     
  10. wizard

    wizard Active Member

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    There's a lot HERE was there something specific?
     
  11. Polock

    Polock Well-Known Member

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    bubble gum, to plug that crack :)
     
  12. wizard

    wizard Active Member

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    Here's a picture of the tank that had open heart surgery & a couple of memory joggers.
     
  13. crow

    crow Member

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    That's come up a treat wizard. Do you need to replace the rubber grommets that hold the side fairings in and if so where do you get them?
     
  14. Hillsy

    Hillsy Member

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    I like the way you've humanely covered up the other 900 so it couldn't see how you ripped the tank open :lol:

    Nice work mate :wink:
     
  15. wizard

    wizard Active Member

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    Just get them from Bunings, Crowman.
     
  16. wizard

    wizard Active Member

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    Finished again, after the tank remodeling & a replacement oil pan (thanks Alive). 8)
     
  17. schooter

    schooter Active Member

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    awesome
     
  18. RickCoMatic

    RickCoMatic Well-Known Member

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    Magnificent.
     
  19. crow

    crow Member

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    Don't know where you find the time to watch cricket wizard. Another inspiration.
     
  20. RangerG

    RangerG Member

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    Wizard. you are a credit to the XJ Bikes Nation!
     
  21. KTA2

    KTA2 New Member

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    Fantastic project! Great looking final product. The polished fork lowers really stand out to me.
     
  22. Bushy

    Bushy Active Member

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    Congratulations on the second coming Wiz', no rain forecast this week you'll
    just need the usual ATGATT. How's the fuel tap performing.
     
  23. cds1984

    cds1984 Well-Known Member

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    Damn sexy!
     
  24. wizard

    wizard Active Member

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    I could smell the gas from the laundry room this morning, yes you guessed it, I forgot to turn it 'ON' :oops:
     
  25. dfknoll

    dfknoll Member

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    Holy wow! She is a bute! How about you fly over here and polish up my XJ! In exchange i will give you room and board and all the "Famous Frankenmuth Chicken" you can eat. lol
     
  26. wizard

    wizard Active Member

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    Picture showing an extra detail suggested by RickCoMatic.
     
  27. redcentre003

    redcentre003 Member

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    Wiz,

    I have a friend in Mornington so I intend riding my bike down that way soon. Be good to coordinate and drop in for a coffee and ask questions on your great restoration project. I'll bring the camera for a side by side comparison (I think yours will win by...oh...a country mile).

    And then I'm sure Rick would be interested in seeing them too.

    Looking forward to catching up in the near future.

    Red
     
  28. streetbrawler750

    streetbrawler750 Member

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    Your bike is awesome!
     
  29. jeff4995

    jeff4995 Member

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  30. TIMEtoRIDE

    TIMEtoRIDE Active Member

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    Yamaha could sell those as a new model !! Awesome !!
     
  31. chuckles_no

    chuckles_no Member

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    Hey wiz... we have the same grips. Haha. That is one awesome bike. I had notions of making mine like that but don't have the experience.
     
  32. Glenn

    Glenn Member

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    Would that be the three stripes on the airbox? Nice little detail.
    The bike is looking very good indeed.
     
  33. wizard

    wizard Active Member

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    Well spotted, or should I say striped. :lol:
     
  34. SecaRob

    SecaRob Member

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    great work wiz!
     
  35. yamyboy

    yamyboy Member

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    Now im looking for a 900 my wife really dosnt like you. Its a beautiful bike
     
  36. wizard

    wizard Active Member

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    Bike was running rough at low revs, so I decided to go through the ignition system, starting with the pick up coils, OK, took the ignition coils off the bike, primary circuits fine, book says check secondary curcuit with the plug caps on, both coils said 20k+ ohms, so removed the caps & they ohmed out @ 13.2k, spot on, so the caps have resistors in them.
    The bike came with the non resistor plugs & I changed them out for what the book says, which is the NGK BPR8ES, I have now put the non resistor plugs back in & the sparks are a lot healthier.
    Funny thing my other xj900 has the same set up R plugs & 5k ohms R caps.
    Who out there is running what ????? Wiz...........
     
  37. Polock

    Polock Well-Known Member

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    copper wires, nonresistor boots, nonresistor plugs, i get enough resistance in everything else i do :)
     
  38. AutumnRider

    AutumnRider Member

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    Wow, nice bike
     
  39. RickCoMatic

    RickCoMatic Well-Known Member

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    I go through enough Plugs that I should be buying them by the case.

    Champions have been my Number One Choice since I learned how to change a Plug almost 50 Years ago.

    You can't get a better Plug!
    But, you CAN spend a lot more for Plugs with aggressive Marketing & Advertising Campaigns.

    If they let you walk down the Grid to look and see what Plugs are the choice of Formula-1 Cars. Champions are the leading Plug of choice. The Champion Logo likes fast rides!

    The Brand has the same kind of following as other quality Products on the market.

    You got those who'll buy anything on sale!
    Those who think spending big money will get them more for the dough.

    Motor men: They just belly-up to the Parts Counter and tell the clerk to go get them a 4-Pack of Champs and they all know which ones are which.

    I uses to buy N9Y's.
    Over the years they have improved the Plug.
    Now, they're NR9YC's.
    They sell millions of them.
    Mostly to guys like me!
     
  40. Polock

    Polock Well-Known Member

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    i've had the same plugs in mine for three years, maybe you should rethink that Champion stuff ? :)
     
  41. wizard

    wizard Active Member

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    After attempting to carry out the 'quick fix' on the starter clutch, one of the rollers, 3 springs & 3 caps, now reside in the oil pan. :cry:
    I will now remove the pan & retrieve the missing parts, after that, not sure.
    Attached is a simple drawing explaining how our mysterious starter clutches function.......
     
  42. Hillsy

    Hillsy Member

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    What was the quick fix wiz?

    I've "re-conditioned" a few starter clutches in my time which involved re-facing the ramps on the outer race (the rollers make a groove in the race over time and that's why they slip). It's a dis-assembly job though - and careful use of a die grinder.
     
  43. wizard

    wizard Active Member

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    The quick fix part, was getting at it through the generator, I have ordered new rollers, springs & caps from Len, but I would be interested in the refacing bit.......
     
  44. Hillsy

    Hillsy Member

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    It's not hard to fix, but you have to remove the starter clutch to do it.

    When you get it out inspect the rollers and the ramps on the outer race (where the rollers travel). Either the rollers are worn / ovaled (unlikely), or the ramps are grooved / not even (more likely).

    The fix is to run a die grinder over the grooves and flatten them out so the rollers travel smoothly against the race and engage with the inner race.
     
  45. Polock

    Polock Well-Known Member

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    one roller, 3 springs & 3 caps, sounds like you almost had it
     
  46. wizard

    wizard Active Member

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    Sarcasm is my favourite form of whit. :lol:
     
  47. Kiwi

    Kiwi Member

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    The other problem is that the outer race absorbs a huge amount of force during the starting process and sometimes cracks. Yamaha use this mechanism on most of their models from this era and I've replaced a number due to cracking around the weakest spot.
     
  48. wizard

    wizard Active Member

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    Why are you guys lining up to give me more problems, how about some solutions................
     
  49. Bushy

    Bushy Active Member

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    Well if you need an extra pair of hands I have some you could borrow.
     
  50. wizard

    wizard Active Member

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    That's very nice of you, Bushy, you could at least hold my jacket while I hit it with a lump hammer. :lol:
     

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