PROJECT 900

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

 

OK, thanks. Looks nice.

 

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?

 

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

 

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

 

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

 

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 .

Where'd all your pics go?

 

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.

 

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

 

There's a lot HERE was there something specific?

 

bubble gum, to plug that crack

 

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

 

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?

 

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:

 

Just get them from Bunings, Crowman.

 

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

 

awesome

 

Magnificent.

 

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

 

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

 

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

 

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

 

Damn sexy!

 

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

 

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

 

Picture showing an extra detail suggested by RickCoMatic.

 

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

 

Your bike is awesome!

 

Sweet.

 

Yamaha could sell those as a new model !! Awesome !!

 

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.

 

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

 

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

 

great work wiz!

 

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

 

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...........

 

copper wires, nonresistor boots, nonresistor plugs, i get enough resistance in everything else i do

 

Wow, nice bike

 

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!

 

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

 

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.......

 

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.

 

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.......

 

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.

 

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

 

Sarcasm is my favourite form of whit. :lol:

 

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.

 

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

 

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

 

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