1981 XJ650 Build

I scored an 81' XJ650 from Craigslist for $100

 

hows it look got any pics

 

I see how this works now. I figure this is a good place to share my build. Last week I got my first street bike, an 81 XJ650. The guy I got it from was going to have his kid build it, but it never happened. He had it for 3 months, before that it sat for around 5 years, probably in a garage. My plan is to build a bobber eventually out of it. I got it as a project I could work on while I recovery from knee surgery.

Today was the first day I worked on it. I pulled the carbs and spent about 5 hours cleaning them. Tooks 3 cans of carb cleaner and 2 metal brushes, but they are much cleaner now. The gaskets and some other parts need to be replaced but otherwise they are in great shape.

After cleaning I installed the new battery I got as well as plugs (didn't have any when I go it.) It turns over and sounds good. After a few start attempts I checked the spark and found that cylinder 2 and 3 don't have any. I called it a night after that. I'm thinking either coil or maybe the battery was to low to power everything. Going to let it charge and try again tomorrow.

 

did you pull all the jets and clean them too and yes a good charge on the battery will make a big difference. waht did the fuel look like in the tank it will probably need a good cleaning.

 

Yeah, all the jets were blocked, gas in the tank smelled something feirce. I wish I could take a picture of smell.... The tank will have to be cleaned with some sort of solvent and some aggregate.

 

buddy of mine used a pressure washer in tank set in the sun to dry...... I advised him dump some alcohol in it to dry out moisture...... you mgiht be able to use clean river pebbles and then rinse with alcohol ..

 

I did some electrical work on the bike today, looks like both coils are good. I get spark on cylinder 1 & 4 and when I reverse the coils I get spark. I found a wireing diagram. I checked the connection point for the positive in the wiring harnase. It was a bit nasty so I cut it out and re-sodered it. Farther down the electrical line I'm pretty sure theres a short. If the ignition is on and I wigle the harnese next to the fuse box the netural light goes out. Havn't found that short yet. Back to the spark issue, I'm thinking it may have something to do with the ground to the coil. It uses a green/yellow wire which is not shared with the other coil. Traceing it back through the ignitor uint it goes to the pick-up coil, might be loose in there. I think i'm going to have to break down tomorrow and find my multi-meter or replace it. Has anyone seen issues with the pick up coil or power not getting to one of the coils?

 

Anyone have any advice to trouble-shoot the electrical system on the coils?

 

After cleaning I installed the new battery I got as well as plugs (didn't have any when I go it.) It turns over and sounds good. After a few start attempts I checked the spark and found that cylinder 2 and 3 don't have any. I called it a night after that. I'm thinking either coil or maybe the battery was to low to power everything. Going to let it charge and try again tomorrow.[/quote]

2&3 use the same coil ...check the ground wire for the coil Mine had a broken ring terminal under the tank only it was a black wire.


OOPS! didn't read far enough. Your already on to it. OBTW those carb bowls were pretty gummy. Not sure if you know but one of those bowl drillings has a jet in the bottom that's small like .3mm and is part of the idle ckt. They are almost always plugged with goo. most install an inline filter.

 

I'll keep an inline filter in mind. I was thinking about running one for the first few tanks of gas then replaceing it incase there was some more goop somewhere else.

I think the CDI box is the issue with the coils. Have a look, leeky cap's are never a good thing to see.

 

How about a pic or two of the whole bike? Nice job cleaning those carbs.

 

Finally got some solder wick and was able to pull the CDI box apart. Heres a close up, I'm not sure thoes caps are leaking. Looks kind of like glue or a sealent or something. Either way, I'm gonna solder it back togeather again and try it out after messing with it. I got my tools back from a friend so this week i'm going to dig into the bottom part of the wireing, I'm still hopefull its a loose wire down in the deepths of the bike....

 

Well after putting the CDI back togeather again I'm getting no spark in any cyilnder. New one from e-bay is on its way.

 

Yeah our CDI boxes can be finicky - even frustratingly annoying when it gets damp out. Good luck with the "new" one!

 

Got the "new" CDI box today. Still no spark in cylinders 2&3....

 

I would put a large amount of money on you're TCI (CDI) being the culprit. You switched your ignition coils both work, pickup coils are pretty indesructable, and finding a shorted wire would make everything too easy. I spent over a month working out this problem when I first started with my XJ. After replacing my suspected kaput TCI with a working one off ebay, I found after that month of troubleshooting everything else that both off my TCI's were Kaput... A third one resolved the issue.

 

Really, you went though 3 CDI boxes till you got a good one? I tried the new one yesterday and it didn't solve the problem. Still no spark in 2&3. I tested the whole system again (as best I could) and still have the same symtons. I even cut the wireing harnase apart and all the wires looks good, no rot or broken wires. The next thing I'm thinking of is the Ignition Pick Up could be off. Although I kind of doubt it because its just a magnit right? The rotor passes the one on the bottom and cylinder's 1&4 spark then the top one and nothing, even though I'm getting 12v from the red/white that connects to the coil. There seems to be something that is causing a short/break/gremlen on the other wire(gray wire?) from the coil, which leads to the top of the rotor in the ignition pick up.

So do you think I should try another CDI/TCI box or try a new pick up first?

Thanks,
Perry

 

I think I have solved my spark issue. I dissasembled the plugs which connect to the CDI box. When I reverse the Orange and Gray wire I get spark in 2&3 but not in 1&4. I can reverse the Black and Brown wires in any combination and nothing changes with the spark. I'm quite confident that the pickup was the issue all along. A "new" one is on the way.

Perry

 

Progress!! I got a new pickup coil from E-bay off of a 81 Seca. Hooked it up and I'm getting spark in all cylinders now. I'm working on starting it now, it's made a few noises and some back fires. I'm thinking the batt is to flat now to do any good and may have a fuel delivery issue. Bike is charging now going to try again in a little bit.

 

So I played with it for a bit, the longest it would run for was about 2 seconds. It backfired a few times, spudders and made some a few other noises. I think the carbs are still durty, going to open them up again tomorrow.

 

Could be as easy as switching the spark plug wires, 1-4 to 2-3 Cylinders and vice versa.

 

It's ALIVE......mmmuuuuhahahahaha....

After cleaning the carbs again, I found the needles were sticking and one had come loose. Sorted the needles out and put the parts in that came with the rebuild kit. And eventually figured out the correct pin out for the CDI box using an 81' Seca pickup coil and it starts instantly. Almost like a new bike, there's no labor in the turning over, just bam running.

Ideling is a whole other story, to keep it running I have to play with the choke, if its max choked it reves all the way up and a little more than half it starts to sputter and dies. Also it spits back and chugs every few seconds or so. Not to sure what is causing this issue. Anyone have any ideas? I ran it open carb, no airbox or filter on it right now. I have pods I'm planning on installing but havn't put them on yet. Still deliberating on the 7th layer of hell....

I'll get a video of what the engine sounds like tomorrow.

Perry

 

Excellent job of bringing her back to life. It gives you a good feeling of accomplishment. Oh and congrats

 

Heres a video of it running. Today when I started it it sounded much better than last night.

http://www.youtube.com/watch?v=kkxK1tsXOY0

 

Update

My fuse box arrived in the mail today. Got it installed just now. I also got the toggle switch and RFID box for the ignition. I'll install them later today or tomorrow. I havn't quite figured out where I want everything.

 

Well, I was trying to hook up the RFID box and must have shorted it out or something. Good thing it was only 9 bucks. New one is on its way as well as some cables, seat and stuff. The good news is that the blue LED toggle switch I got to replace the ignition works.

 

Made a lot of progress this weekend. Welded a plate in place for the Ammo Can Electrical Box, figured a way to mount the solo seat got some wireing sorted.

Its about 85% finished right now. I took it out for a test ride and it spat up a bunch of oil, chocked and stalled at low rpm's. Looking foward to tuneing it.

I think this is all that's left:
Needs carb tune, oil, tires, cables, handlebars, speedometer, rear fender, tail light, blinkers, electronics to fit in ammo can, oil not to shoot out the tranny vent, brake pads/bleed the brakes again, gas tank liner, 4 into 1 exhaust and finally matt black paint.




First time welding so its not the greatest but it works......


Ugly as sin, but functional.

 

LOL Rock hard...


its great to see action photos...

I love it that these bikes you can do just about anything and or give it a go kinda attitude... well done for your welding.. although I wont comment.. I think you did a fantastic job for your first go!!! well done!

 

wow I've been busy on my bike. It's like 90% finished right now. I'm walking about a week or so ahead of schedual so its been full throttle to get the bike street ready, no more mods for the time. I need to get out riding. I've been playing the carbs and doing some tuneing. I put everything togeather and found that cylinder 3 wasn't working (the pipe was colder than the others) pulled the carbs and cleaned it out again. Thats what I get for not running an inline fuel filter when theres flakes of rust in the tank. I got an inline fuel filter now the take liner chemical stuff will be here on wed as well as some new tires. I benched synced the carbs twice using this artical as a guide line. http://xj650.blogspot.com/2009/04/how-t ... carbs.html
Turns out it helps if both paperclips are have the same dementions...... anyway.... Today when I was working on it cylinder 1 wasn't fireing. Turns out the plug was just fauled a little carb cleaner and a wire brush and I'm running on all 4 now. I turned the idle screw out a little and it idels perfectly and is very responsive when the throttle is turned. I can not belive how much power this bike has for its size. It want's to do a wheelie while shifting into second gear. Un-real. I did an oil change last friday with parts from www.partsnmore.com the only oil that is left is in the forks. I got seals but dust boots have been a little harder to get (out of stock on e-bay) I have sourced a new pair and hopefully will be here by the weekend. I re-attached all the orginal rear fender and lights; supprisenly everything still works.

I went for my first long road test tonight, rode for almost an hour and didn't get stuck or break down. Success!

The to do list is getting much shorter:
Bars, exhaust, forward controls, make all the wireing fit in .30 cal ammo can, front forks, speedo that works, loose the tach, replace lights with led one's, replace mirror with more stylish one, motorcycle license and title for bike. ;-)

I'll have some more detailed pix in a few days. once I do the tank and get new tires.


BTW: PODS and stock jets with stock exhaust work PERFECTLY!! (clean then clean again, bench sync, and tune with idle screw) no poping anymore after I tightened all the bolts on the exhaust and replaced the vacume tube.


Test ride around the block


The obligatory "I'm cool standing next to my bike" picture. ;-p

 

I'm impressed.. Are you going to put side panels on or leave the can in full view?

 

I only have 1 of the side panels, I'm was planning on leaving them off anyway. I'm going to add 81mm Mortor cans on the side as saddle bags. They will match the .30 cal can and hopefully will look good.

 

Yeah.. Should do.. Leads to an idea of camo coloured bike to complete the theme??

 

sounds like a pretty cool and unique idea. Do you have any teaser pics of the mortar cans or .30 cal can?

 

Nice, I am in the proccess of building my xj650. I am pretty much doing the same thing with the ammo boxes. I have a few laying around. I am going to a minimum on wiring, and was going to do three ammo boxes. Dose a battery fit inside that box in the center? Also I was considering some thing kinda odd. My saddlebag ammo boxes were going to be removable, and are going to house my brake lights on the back of the boxes. I am thinking of doing this just not sure yet. I was going to run the brake lights with plugs coming out of the boxes some where so I can unplug them and remove them. I am just trying to figure out sizes. I have the bigger boxes I am not sure if my battery will fit in the smaller onse but It looks as though you have a smaller box that works.

 

Progress today. I managed to fit all the exectric's into the ammo can and cleaned the bike up a bit. The new tires were susposto be ready this afternoon but they wern't, so much for a morning ride tomorrow. Anyway in an effort to get a title for the bike I managed to get an 83' XJ650 with a Yics engine 17,000 something miles for $150. The engine had been sitting in a yard for about a year. Turns out I can turn it over with a wrench and plugs in. Seems to be good. I put it back to togeather and its just about all there. Might make this one stock or a hard tail or something. Here are a few pictures of the ammo can and how it sits today. Also, I got POR-15 tank liner to take care of my rust issues. I lined the black tank took about 2 hours or so came out pretty good.

I am sooo ready to put the tools down and start riding.

Right side.


Left side.


Waiting for tires. The stock fender will be replaced in a few weeks. Need to get some riding in first.


Came with 2 boxes of stuff..
'

Shiney...


All put back togeather again

 

I like that seat. You need to put a cover on that box or it'll fill with water in rain and rust. Or doesn't it rain where you are?

 

haha.. it rains like 2 or 3 times a year in vegas... Got tires on the bike gone riding for the rest of the day.

 

Rode about 250 miles today, no break downs = Awesome! That bike is realiable!

 

nice to see another fellow xj owner here in vegas

 

xtrmbldr911 for sure! We should get togeather and ride sometime

 

Most definatly ^^ ill send you a message once I get mine running right

 

Rode out to Laughlin for the weekend. I've ridden around 450 miles on this bike now.

Some thoughts on my bike:

I need a bigger more comfy seat for longer road trips.
Having a mirror on the left handle bar would be nice in traffic.
Different bar's would probably be a little nice.
Different grips are going to happen real soon.
Throttle lock would be nice also.
Ear plugs are a must as my helmet is crazy loud with wind noise.

Heres a few pictures of me riding.

 

LoL.. You'll find your helmet a lot quieter if you closed the visor.

Careful with earplugs, in some places they're illegal, and they really cut you off from your environment. I have a pair that have a pair that have little cables on them so if I have to speak to the law for any reason, I can take the earbuds out at the same time as removing my lid, but I don't always wear them..

I have to ride 200km to and from work every day, and in heavy traffic like we have here (I'll guess you get it when you're going into Vagas) it plays with your balance also.

 

haha.. I get lots of wind noise when the visor is closed or open. It was really hot comming up that hill so it was open. Its really only an issue at 60mph+ I don't need the ear plugs in town. 200km commute is a bit much ever day...

 

So I Left a friend’s house on my way to this house party across the freeway when a few blocks on the bike sputtered then died at a stop sign. Now I knew that I was low on gas when I left, but when doing fitting my gas tank I noticed that the petcock had a RES setting opposite the PRI. RES I took for Reserve Tank. “No problem, “ I though as I wheeled the bike across the intersection and onto the sidewalk. I felt pretty clever as I moved the petcock lever to RES and sat there while the carbs filled up. The gas station I was heading for is a few miles up the road; straight ahead on Spencer and to the right. So after sufficient time for the carb to be nice and full of gas I hit the start button, no need to choke it cuz it's already warm. Or so I though. The starter motor gave it it's all to no avail, full choke and everything in-between could not get the bike to rev to life. Feeling less clever than when I moved the petcock to RES, I open the gas tank and some dust blew out, it was that dry inside. Apparently the RES setting does not work on my bike or more than likely I didn't put the petcock back together correctly. Either way I was not feeling clever at all at this point; it was still a mile to the closest gas station. I started walking, well pushing my shiny bike that was now dead weight through the road construction. I headed for the closest gas station, which in Vegas is never very far away. Usually there are at least 3 within 5 miles of any point in town. You'd think we couldn't plan fuel stops or read gauge’s with that many........ Anyway, it's just about midnight by now so luckily I wasn't competing with the afternoon heat. I pushed the old XJ a good half mile to Eastern where it was a nice downhill-ish sidewalk ride to the station. As it turns out the tank holds 3.3 gallons of gas. I was felling slightly more clever as I pulled out of the station and twisted the throttle wide open.

 

One more thing on the POR-15 I used. The liner looked pretty good untill I felt around in the tank and found a large pocket where the liner had lifted from the inside of the tank. I phoned POR-15 and they were sure that the liner gets air pockets like that because of mosture in the tank. They sent me another kit with a solvent for the liner for reduced price and free shipping. After talking to Sully's Cycle Shop about liners I'm of the oppion that they are really not needed. The POR-15 strippers cleaned all the rust out of the tank amazinly well. Once its down to bare metal it back to it's "orginal" condition right? So if it rusts up in another 30 years so be it, I'll probably have ridded it into the ground by then anyway. This weekend I'm going to get the rust out of my tank and disolve the liner in the back tank. Rust may have been the problem with my petcock not working on RES now that I think about it, cus theres some big chunks of rust in there I wasn't able to remove with the magnet...

I'm holding off on all further mods to the bike, fender, bars, grips, RFID and stuff because I got 5 complants from the home owners association and 2 new by-laws passed against me working on "restoring/working on any vehical in the garage in a mannor that is disrupting to the neighbors." or some garabge like that. Dang entitled HOA president!! I'm moveing at the end of the month to a place where you can have hobbies in your garage and if you anger the neighbors they come over and yell instead of pass laws behind your back.

 

That is bullshit man... When I first got my gsxr it had sidewinder header on with a completely gutted yosh pipe on it. When I started it it hurt my chest. That f'er was LOUD! I was just starting it to try and get it running right and my neighbor across the street came out of the house waving her arm at me up in the air like an old grandma... hahahahah... I apologized to her husband later and he told me to ignore her. Needless to say I waited until I got my new exhaust (V&H ss2r) installed before doing anymore work.

Good luck with moving and making anymore progress on the bike.

 

Ah. Neighbours. You gotta luv em. especially the pretty ones when their boyfriends ain't around. Lol

Careful what you do with your tank. With the POR15, the metal ready prep causes the tank to flash rust, you just need to sneeze in it's general direction, even in a dry place like Vegas. If you really don't want to put another liner on, use the marine clean to clean the inside, then leave it at that.

 

I used the por-15 on my Seca tank. I wish I would have held off until I was sure I was going to use it, because now I'm NOT and need to get another kit to do the 750 Maxim tank I AM using.

 

Good idea on the metal ready. I'll try that. I remember the instructions saying something about flash rusting, I wasn't to worried about it because its so dry here. But I guess it could rust from the mosture in the air right?

koolaid5 - when you did the seca tank, how long did you wate before poring the liner in? I waited about 20 minutes and had a heat gun in the tank the entire time. When I porred the liner in, it was hot to the touch and I still go a bubble.

Yeah having neighbors who's only hobby is watching TV and spying on you sucks. Can't waite to move.