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'82 XJ 550 Maxim project finished. Will do it again next yr.

Discussion in 'XJ Modifications' started by chuckles_no, Dec 28, 2009.

  1. chuckles_no

    chuckles_no Member

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    When I bought this bike it had 8,670 total actual miles on it. The guy who had it before me bought it from the original owner and both people didn't take very good care of it. At one point it sat outside of a shed at a cabin up north for 8 years with no maintenance at all.
    Since I have had it, it has had the piss beaten out of it. It now has about 14K miles on it (odometer shows 12,400+ but was broken for a couple thousand after the deer crash).
    Between my friend, Ev, and me, it has been raced, dropped, wheelied, jumped (on accident), used as a dirt bike, ridden hard, and I hit a deer in Douseman wisconsin in August, busting up the front end pretty good. So now, after coming so close to buying the Hayabusa (to the point of having $2,500 aside on it and losing $500 for backing out of the layaway plan) I am set, fully, on making this little xj shine again. This is my official progress forum post which will include before, during and after pics, and also progress reports and explinations.
    You can see a lame startup on youtube as well. And if you are really bored... listen to me play guitar... hahaha
    http://www.youtube.com/watch?v=xd8o9aPCLWg

    [​IMG]
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    [​IMG]

    By the way... that isn't my garage. Just using it til I move the bike...

    The bike job is kinda a tribute to my best friend who helped me beat it to hell. He died in a fatal car accident on Thanksgivivng day.
     
  2. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Why aren't my damn photos attaching?
     
  3. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Probably because they're bigger than 500X500.

    Get yourself a photobucket account; then be sure you resize your pics to something civilized like 1024X768 so they aren't too huge. Then you can imbed rather than attach.
     
  4. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    How do you resize and how do you imbed? LOL. I am a total technotard. Engines and things that might have grease, bolts, need vice grips, might rust, etc... I can do. If it makes noise I can make music... but if it has memory, a mouse, uses gigs and megabytes and stores info... I am lost...
     
  5. iwingameover

    iwingameover Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    [ img ] your url here [ /img ]

    no spaces
     
  6. RickCoMatic

    RickCoMatic Well-Known Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Go to:
    http://photobucket.com/

    Register.
    Upload photos.
    Crop and Resize pix for forum size ... (Automatic)
    Use "Share" function.
    Auto-copies LINK.
    Paste LINK into Post.
    Badda-bing, ... Badda-boom.

    [​IMG]
     
  7. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    HEY... I got the hang of this pic pasting... or imbedding thingie!
    Man... now I am going to annoy the hell outta you all like a gramma with baby pics. LOL.
     
  8. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Here are some of the new parts I have for "Road Rash" so far... still have a lot more coming and more to get or do...

    Headlight... (old bucket vs new bucket made from 2 half assed buckets)
    [​IMG]
    [​IMG]
    [​IMG]

    some odds and ends (master cyclinder and caliper rebuild kits, brake pads, blinker stems, MAC 4 into 1 exhaust, handgrips, billet style mirrors)

    [​IMG]
    [​IMG]
    [​IMG]
     
  9. FABFABINC

    FABFABINC Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    It will SHINE with all those new parts enjoy!!!!!!
     
  10. lopezfr2

    lopezfr2 Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    ill take the slip ons from your old exhaust if you don't want em. pm me.
     
  11. RickCoMatic

    RickCoMatic Well-Known Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Would you please take the time to resize the Photos.

    We'll be able to see the Bike and the other details in Photos that are not so large.

    Thanks.
     
  12. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Sorry bout that. Still getting the hang of this picture thing.
     
  13. schooter

    schooter Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    chuckels, if you're improving EVERYthing on this bike.. i jsut bought these:

    http://cgi.ebay.com/ebaymotors/ws/eBayI ... K:MEWAX:IT


    I was going to do a write up and take some nice photo's of them until I remembered I never asked my parents or anything, so they're not going on until spring break or so, infact, I shipped them to my dorms, not my house (I hope)

    but ill be glad to give you measurements and stuff if you want

    I know alot of people are looking for alternatives to the shocks that pretty much broke (they wont work for poop) after 5K miles.
     
  14. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Those definitely look like pretty sweet shocks but I am already getting the progressive gas shocks. But I definitely appreciate it. And I am eventually going for everything on the bike. The electronics (silinoid, wires, relays, etc...) are going in a cylinder and I am going to bolt on a battery box next.
     
  15. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Got some more goodies ready for Road Rash to post. So I am going to hold off on doing the cam mods for now. Still going to do it and have the cams to be modified on the way. But for now the engine runs fine so that job can wait. Instead I need to do the wheel bearings, suspension, charging and electrical system, brake master cylinder and caliper, and so on. While the engine is still good I am going to do the whole bike before any engine rebuilding. That way I don't have a shined up engine while my front wheel is grinding through the axle or something gawd awful like that. Haha.
    Oh yeah... pics. Seat redone with a Saddlemen seat cover, new NOS tank (at TS Customs as we speak getting the paint scheme done, new turn signals, handlebars (put those grips on there just to see what they'll look like), and new levers.
    [​IMG]
    [​IMG]
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    [​IMG]
     
  16. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Nothing too important... just a couple of photos. One is some parts I shined up to look almost new and my new speedo. I can't wait til I can actually get to doing the actual work on the bike. The tank is at TS Customs and won't be done 'til late feb or early march. But the wait is worth it. The guy is bad ass.
    [​IMG]
    [​IMG]
    Notice I removed the black paint from the pegs and shined them up. I like the bare metal look better.
     
  17. schooter

    schooter Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    I REALLY like what you're doing with this bike, those grips are hawt.
     
  18. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    So I am doing the front sprocket cover next in my shining stuff part of the project. (there are a lot of things I am doing or planning at once)
    What a nightmare that was. There was goo, grime, chain lube, asphalt, sand, and, for some reason, glass on the other side of the cover. I washed it in soapy water but am too tired to start buffing it up. I am going to be doing something to this bike every day til I take it out for riding in the spring. I am sick of winter. Can't wait to get the tank back, though.
    Most of the paint on the frame is ok and will be fine after a good cleaning up. But the swingarm is beat up bad. Never took a swingarm off but I kinda want to have this one painted. I could probably do it myself. But I am actually considering doing something really wierd. the tank is going to be High gloss black with red letters and detail. I want to paint the swing arm red too. And I know it wakes for crappy rain riding but that front fender is going bye-bye. Don't plan on riding in the rain anyway and guess if I do I am getting wet anyway. But I am keeping the rear fender as it is.
    Ok... enough babbling. But this thread is also my diary for everything I am doing with the bike so... blah blah blah.
     
  19. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Front sprocket cover:

    This is after washing in soapy water. It was bad...
    [​IMG]

    After the shine job. It isn't perfect but I don't really want it to be. I took the picture with the reflection of my hand to show exactly what I am going for with the engine. Not quite mirrors but very shiny.
    [​IMG]
     
  20. FABFABINC

    FABFABINC Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Very nice Chuckles!!!!! Nice job
     
  21. seaguy

    seaguy Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Looks good. A little Mother's now and then and they will stay that way.
     
  22. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Ya... just got a bottle of the mag and aluminum polish. I also use that sealer but that is like a once a year sealer. But the polish is all I really need.
     
  23. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    So the stator cover was almost impossible. It is pitted from road rash so bad that I was affraid to go any deeper with the prepping for the buff job. I got them mostly smooth and then got everything evened out. Definitely getting the hang of this shining up things. I just need to go over the black and red details.
    [​IMG]
    And this is partially through the rear wheel assembly. Checked the bearings and they are still in excellent shape. Sealed too so I am going to just keep them. but replaced the seal and reseated them. New brakes and completely cleaned the hub with brake cleaner. Just showing the right side of the hub, prepped for shining up. too tired to do it now.
    [​IMG]
     
  24. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Rear wheel finished. just waiting on the pullers from chacal at XJ4Ever. Should have them tomorrow or friday and then onto another part.
    [​IMG]
    [​IMG]
     
  25. frankenbiker

    frankenbiker Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    awesome can't wait for the finish product
     
  26. seaguy

    seaguy Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Nice lookin seat. Mine looks like a boat!
     
  27. vintagerice

    vintagerice Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Chuck... what are you using to get that degree of shine on your covers?? Wow looks awesome!

    Rob
     
  28. wamaxim

    wamaxim Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

     
  29. jserna66

    jserna66 New Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    doing a great job. looks real good.
     
  30. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    I am almost losing my confidence in this thing I am doing with my 550. I plan on just replacing all of the cables... except for the speedo. That was JUST done before storage. Also want to get new progressive shocks for the back of it. I have so much already done but it is definitely not even a good start. Honestly... I am affraid to mess with the motor. I have spent about $2,200 on this bike since I put it in the garage for winter. It is a tribute to my friend and also the first real project I have ever had on a bike or car and the first time doing it has been more than talk. But every time I go see the bike I see endlessness. The head is so filthy and I am affraid of taking any part of the motor off. If it was just a jusk bike It wouldn't matter but I don't want to break anything. As far as elecrical goes... Gawd... I don't even want to touch it. Trustme... electrical and me do not go well.
    The frame and swingarm need to be painted but if I strip that bike it will be a mess instead of a project.
    Anyway... just can't wait to ride the damn thing. Maybe fully restoring what need restoration and customizing where I want to customize all in one winter is unrealistic.
    But that is my progress on my bike. Got the new exhaust headers on and the new handlebars, grips, mirrors, and conrol levers on there. It does make a difference.
     
  31. schooter

    schooter Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    you dont need to pull the engine apart, it's fine, just adjust the cam chain pensioner, and the valves. as far as cleaning the engine, toothbrush, foaming citris engine cleaner, simple green, and so on
     
  32. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    I start with walmart grade scotch brite. the green stuff. But you have to go fast and light and don't stay in one spot with it. Get all of the big stuff off, the deep seated garbage and anything, including old clear coat off with it.
    Then I move to a finer grade scotch brite made for automotive painting.
    After that I use 800 grit, 100, 1200, and 1500 grit sand paper and in that order as suggested by RickoMatic, I believe.
    Get everything as smooth as possible. I use dry sandpaper until I get to 1200 grit then just use water soaked 1200 and then 1500 grit.
    Then I use the mother's aluminum stuff or the metal shine. I just dump it right on the metal and smear it around with the Mothers polishing ball. I use the small one.
    I then just keep buffing it. Every now and then I wipe it down very thouroughly and get all of the compound off and shine it up with the rag. If it isn't what I am satisfied with, i go through with the compound and the mother's ball some more and just keep doing it.
    When i am satisfied I clean it up very good. The I use the Mother's polish and give it 2 rounds of that just using a clean rag.
     
  33. vintagerice

    vintagerice Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Gotcha...thanks,

    Rob
     
  34. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    So I guess I should post a few pics of my progress. Nothing too spectacular and nowhere near complete but here is where I am at so far on the bike. Got the blinkers done in the back and the mac exhaust in place. Both turned out nice.
    The void where my airbox once sat will be covered with diamond plate. I love that look so I am going for it but more toward may or june. The battery and the electrical in that area will be moved to a box or just relocated in general to keep easy access and to make room for the diamond plate side covers.

    4 into 1 installed
    [​IMG]

    Started on the handlebars, new grips and mirrors. Not nearly finished with this area though.
    [​IMG]
    [​IMG]

    New blinkers. They are much smaller and I just went without the stem. They are much brighter than stock.
    [​IMG]
    [​IMG]
     
  35. vintagerice

    vintagerice Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Really Like the mirror's Chuckles... Like the lights too but wonder if they will give off enough light. For safety I mean.

    Rob
     
  36. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Actually I was wondering the same thing but when i went to check them... after installing, they were considerable brighter that the oem signals. They are much smaller and way closer to the frame but they are bright. I am kinda nerdy and Have actually been considering an led kit as well... for added coolness, but the bike is going to have a lot of black and the leds will make it more visible at night.
     
  37. FABFABINC

    FABFABINC Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    Coming along nice Chuckles. I got the same grips they are actually very good
     
  38. pathebert

    pathebert Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    The bike looks great, Where did you get the grips?
     
  39. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    I got them from milwaukee cycle on ebay. I have noticed a couple of bikes on here with the same grips
     
  40. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    So I am far from being finished with the project. I will start posting pics as work progresses but for now here are some of the things I am working on...

    -Ignition switch relocation
    -Choke/enrichment lever relocation
    -chrome handlebar switches from mikesxs.com
    -front brake system overhaul, including new rotor
    -battery relocation and diamond plate side covers (going to make them easily removed and replaced for battery and electronics access
    -speedometer mounting along with home made indicator lights (neutral, turn signal, oil light, and high beam indicator)
    -a lot more clean up with the electrical... especially the cluster that runs from the alternator, starter, and that area up behind the motor to the harness. Some of it needs to be replaced.
    -new air shocks for the rear
    -front fork rebuild (possible change to seca forks and dual disc brakes in front)

    So as I can get to it and really spend time with the bike, i will be taking pics. I want to have this thing totally done by riding season. Well... at least done with what I am doing this year.
     
  41. schooter

    schooter Active Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    chuckles.

    im going to state some of my opinions.
    choke relocation- I think it would be super cool to have a pull type choke like on the older cars...
    now, I wouldnt recommend the seca 750 front end, because of the bogus anti dive, rater get another xj dual disc setup. buy some SS lines too. and you're going to need to use a different MC that the one that's on your maxim.

    I RARELY think that anything other than factory side covers look good

    as far as air shocks... I dont know much about them

    once again, those are all my opinions, they're like butt holes, everyone's got 'em and they stink.....
     
  42. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Not relocating the ignition switch now. Mounted the headlight bucket loosely and just put the cover back on the handlebars that also goes over the ignition... then with the new speedo on the left bracket/guage mount, it looks pretty sweet... I am actually changing my whole mind for this area. I am still doing without a tach... only using one when I need it, and in the place of the right side mount I am going to convert and identicle speedo to my indicator light housing. I have some ideas on how I can do this tastefully. The 4 lights will be around the edge of the circle and I want to try finding a small yamaha symbol for the middle that will light up when the bike is turned on.
     
  43. Krashen

    Krashen Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    I just have to say I'm going to be following you the whole way I want to bob my 550 out but just seeing what your doing makes me wish mine was here with me so i could work on it. Great job so far man keep it up i look forward to seeing more pics and updates!
     
  44. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    They'll be coming. 3 main things I am working on at the moment are the wiring for the front headlight, indicator lights (N, high/low beam, oil pressure, and turn), the mini speedo, turn signals, etc.... easy stuff. Am redoing the whole brake system, and making side covers out of aluminum diamond plate.
    Here is what I have so far on the diamond plate covers...
    24x12 sheet of 1/16 diamond plate. A new floor mat from a ford pick-up, and a dream... haha.
    If you look at kevinelevin's bike... when it was yellow and still with the sof-tail frame, he used diamond plate and it was so bad-ass that i am copying him a little.
    Cutting out cardboard templates in the shape of the side covers I want.
    If the rectifier/regulator is too far out, I will cut out the rectangle in the diamond plate and attach a small scoop to A- make room for it and B- make sure it gets air to it for cooling purposes. Hopefully I won't have to do that and, from kevineleven's advice, i might not have to.
    I want three mounting points on the covers. I am going to use (and hopefully this will work) footpeg frame mounts for the side cover mounts. They are a two piece, clamp mount that will fit tightly around the tube and have a threaded part that, normally, is there to screw the peg adapter in. I am going to be bolting my side covers to those.
    The side covers will be the diamond plate cut out in the desired shapes, holes drilled for mounts, and the ford floormat cut to the same shape and slapped on the inside of the diamond plate for dampening reasons and to separate the metal plate from the electrical they will be covering. They will be finished off with a rubber or vinyl trim... most likely something that goes on car doors or something. Thats my plan.
     
  45. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    This is a copy of the order I just sent to chacal at xj4ever. Maybe I am going too crazy with this project. Haha. One thing is for sure... I shouldn't have a problem stopping. Only problem is I have to call the bank and have a limit lifted on using my debit card online like for paypal but I am about to do that right after I post this. This stuff will all be here in less than a week I'll bet.

    HCP3037 OEM front master cylinder RESERVOIR COVER
    $ 13.00
    HCP3034 OEM front master cylinder RESERVOIR DIAPHRAM
    $ 8.00
    2 HCP6558 Replacement Master Cylinder Reservoir Cover Plate flathead SCREWS
    $ 1.75
    HCP1775SET2 OEM brake caliper BLEEDER SCREWS, set of 2:
    $ 20.00
    HCP3474SET2 OEM front brake caliper MOUNTING BOLTS, set of 2:
    $ 2.75
    HCP2230SET2 OEM front brake caliper mounting bolt LOCK WASHERS, set of 2:
    $ 2.25
    HCP2508SET2 OEM front brake caliper mounting bolt FLAT WASHERS, set of 2:
    $ 0.95
    HCP2830BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with black sheathing.
    $ 44.95
    HCP2831BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with black sheathing.
    $ 49.95
    HCP1075SET4 OEM brake hose junction UNION BOLTS, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 4:
    $ 7.25
    HCP1077SET4 OEM brake hose union bolt copper CRUSH WASHERS, set of 4:
    $ 5.75
    HCP1597 Aftermarket master cylinder CIRCLIP PLIERS, each:
    $ 17.95
    HCP5908 All hail the great MITY-VAC
    $ 39.95
    HCP8546 Aftermarket ONE-WAY VALVE BLEEDER HOSE KIT.
    $ 16.95
    HCP9955 Aftermarket 3-shoe brake CALIPER CYLINDER HONE
    $ 17.95
    HCP9958 Aftermarket replacement set of three brake caliper cylinder HONE SHOES, 400-grit.
    $ 5.95
    HCP1742 Aftermarket master cylinder piston bore FLEX HONE
    $ 37.00
    HCP6060 Aftermarket petcock Complete DELUXE REBUILD KIT
    $ 52.00
    HCP2690 OEM original THROTTLE CABLE
    $ 24.00
    HCP3541 OEM tachometer cable drive gear HOUSING RETAINER BRACKET
    $ 3.95
    HCP3537 OEM tachometer cable drive gear O-RING
    $ 4.95
    HCP3539 OEM tachometer cable drive gear (on cylinder head) OIL SEAL
    $ 5.95
    HCP3540 OEM tachometer cable drive gear CABLE ADAPTER
    $ 11.50
    HCP7521 OEM tachometer cable drive gear housing BLOCK OFF CAP
    $ 7.50
    HCP270 Aftermarket oil filter PRESSURE RELIEF BYPASS VALVE & COVER MOUNTING BOLT
    $ 17.95
    HCP2279 Aftermarket oil filter bypass valve and cover mounting bolt O-RING
    $ 1.50


    Subtotal- $ 421.65

    Shipping- $ 5.00 priority mail

    TOTAL: $ 426.65
     
  46. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Sooner than that.......... :D
     
  47. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    So I have a lot of parts coming which should make my brakes to notch and also cover my tach drive port the right way. Made this last night and need to finish cutting out the other side cover. This is going to be for the right side, of course. [​IMG] More pics on the way as I finish them
     
  48. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Haha... I have ordered from you twice, and both times I have had the stuff 2 days later. Making another list of needed thingies. After the brakes I am doing the front forks and if these shocks I got for $60 are as bad as I have heard... won't be able to settle for that.
     
  49. chuckles_no

    chuckles_no Member

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    Re: So this is the '82 xj550 Maxim I have been talking about

    Latest on "Road Rash":
    (the tank is a rust bucket I just use for perspective. The real tank is undergoing good medicine.)

    The garage...
    [​IMG]
    [​IMG]

    The side cover and shocks...
    [​IMG]
    [​IMG]
    [​IMG]

    What I have decided for now for the handlebars, speedo, and that area...
    [​IMG]
    [​IMG]

    The bike... so far...
    [​IMG]
    [​IMG]
     
  50. lopezfr2

    lopezfr2 Member

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    Re: So this is the '82 xj550 Maxim I have been talking about.

    i like what you're doing with the bike except the side covers. i don't mind the stamped look but they just seem out of place with the rest of the scheme of the bike. although you may have just helped me decide on the gauges for my bike. i was going to replace the stockies with some 2 1/4" gauges from mikesxs but looking at what you have on your bike they seem just too small. might just replace the housing instead and give them a nice cleaning
     

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