Project: 1981 XJ550

You probably won't believe me, but I traded a laptop and a PSP (with games of course) for these TWO motorcycles!

Both are 1981 Yamaha Maxim 550's. I picked them up last night. The blue one is a parts bike and the maroon one is complete and runs like a champ. So far all I've done is put them in the garage. I got plans though amigos! I'll start my build thread and see where it goes. But I think it's a pretty good deal huh? Both clean titles, and even the parts bike has plates and tags. Sweet!

Runs strong...




Parts bike...


Pipes look good...




I'm really in love with this Maxim here...



And if I can come anything close to this I'll be more than happy. I've not seen may Maxim builds here, or anywhere for that matter. Most of the Maxim's I've seen go straight to bobber. I'll see where I come out, but I wanted something more like that red bike.

I can't complain, I got a nice little Maxim that runs strong, and a parts bike. So I can tear it apart at will. I'll post pics and updates as I go along, but I suspect this might be a slow build. Just got a lot of projects going on at the house as well.

Any ideas, feedback, help, info, etc would be more than welcome. What I would really love to do, is a mono-shock in the back, although, I've never done anything like that before, I really like the mono-shocks on the older bikes. The only reason would be to put a fatter rear tire. Other than that, maybe a fork swap and custom tail of course. We'll see, my skills are limited, but I'm not pressured because I can just ride this...



in the meantime.

looking for a manual online as I write, thanks for looking and wish me luck amigos!

 

Real quick, pics from when I picked them up. I know I already posted about the pickup, etc. But my GF took the pics and was wondering why I didn't use hers. So here goes..

Ready to load...



Gonna back it in so the weight is on the front of that tiny u-haul trailer...



Why doesn't this thing have reverse!





And in place...



Strapped down and ready to roll! You can see hte parts bike in the bg.



Don't have pics of the other bike being picked up cuz it was dark by the time I got back there. Anyways, the guy that traded me (the blond) was really nice and helped me load each bike, even let me borrow some ratchet straps. Great guy!

 

Got a little time last night to start the tear down. Here's some pics of before the tear down begins.

***DISCLAIMER***
This is going to be a slow project. One reason being the funds issue. Gotta try to build this whole thing using *extra* money. We all know how hard that is. I've got a full parts bike and am hoping that between the two I can muster up some cash for the project.

There are gonna be tons of pics, partly because we love pics here and second because alot of this will be new to me, and I want pics of each step so I can reference for myself later. So if I bore you with a "seat removed" pic, it's simply for the greater good of the build, and my own sanity. HAHAH.








Seat removed...


Sissy bar gone. I've got two sissy bars no, hopefully I can sell them!


"Lunch box" removed. I don't know if that's what you call it, but it's the box behind the seat that you can store stuff in, like your lunch, or tequila, or rockets, you know a compartment of sorts. Anyways, it's gone.


Next is the rear fender and brake light...



Now the side covers. They are in great shape too, hoping I can get some cash out of them. All this stuff, the battery and all that has got to go!



Chainguard....


Now the left and right passenger pegs. Since this will be a single seater, I won't need any of this and will be able to clean it up pretty good I think. I'm gonna keep all the removed stuff in a box and weigh it all. That way at the end I can post how much weight was shaved, etc..

Left...



Right...

Had to take off the brake pedal...

Done


Now the undertail, I think that's what it's called...

This thing..


I started to work on the highway bars but ran into some sticky bolts, etc. That's ok, blasted them with some PB as well as a bunch more rusty bolts and will get more done later.

Here's where I ended for the night..




Not too bad for a couple beers and bs session. It's starting to give me ideas and hope. It currently runs great but I do plan on pods and exhaust changes.

 

Ok so I need some advice amigos. Here are the 2 bikes that I am looking at for inspiration. The thing is, they are both different directions, so I need to decide.

Bobber...


Or this one (is this a bobber too?)


Of course each would have my own spin, etc. Here's my thoughts. I really want to do clip-ons, so I'm almost pretty decided there. For exhaust, if I go with the top bobber, I'll do two supertraps and keep the general layout.

If I go with the red one, I'd most likely do a 4 into 1 and do one supertrapp. Yeah I really want to do a supertrapp for some reason.

Anyways, either way, I'm looking to go inexpensive, I like the wheels so I'll paint and keep them. I'd of course get new tires. I'll try to keep as many parts as possible. The top bobber would require more frame mods but they both look relatively easy and inexpensive. Well not really easy but you know what I mean.,

So I need some feedback amigos. Which do you think would suit the frame, etc better. Advice? I've got a lot of work ahead of me, but I want to decide to I can put my head down and charge forward. Thanks in advance amigos!

 

Ok so got some more tear down done today. It's starting to take shape..

Fender before...


Fender after....



Mirror...


Gone...


The head light was such a pain in the butt! There was so much wiring in there!


Ignition cover. Hopefully I can sell this piece...



Highway pegs left and right...








Gonna clean em up and see if I can't sell these as well...


Found this little prizes on the forks. Sure I can use em somewhere


Took the bars and all the controls off, then turned em upside down just to see what it would look like, etc. My little bro loved the look. I'm still thinking clip-ons.


And this is where I left it for the day...


I'm really starting to like this frame. It's not as ugly as I'd thought once I cleaned it up a little bit.


I don't have a socket big enough to take off the triple clamp so taking off the forks and all that will have to wait a it. Plus I wanted to go for a ride. I'm definitely decided on the red bike style. I think a different tank will do wonders.

Let me know what you think amigos and thanks for looking!

 

That's about it for this week. I don't have the tool to take the triple off so I'll wait until this weekend to pick it up. Then gonna take the clamp off and do the forks. Then paint the fork tubes. Any suggestions or tips would be greatly appreciated amigos! Thanks for looking!

 

PS. If anyone can offer tips on how to get the mufflers off that would be great! I don't want to have to cut them off...

 

Good score!....any time ya can swap off plastic & pcs for a couple of examples of alloy & steel yer ahead of the game........

There is an XS triple build on CF to give the once over......search for a XS triple streetfighter project......don't have the builders tag but he also has a knock out xs 1100 cafe he built also....food fer thought......

Careful with the exhaust......seems that these things rotweld solid after 20 years or so.....PBs a good start. Try to get all the attachments free before ya drop everything...IE bottom mount, head studs ( CAREFUL these are made of yamacheese)...a bit of heat helps alot......

Welcome to the forum and the world of XJs.........They are solid as a stone when ya get em sorted...but, sorting them out is the trick.....You will find the XJ forum a great help in that dept.

My page on the subject;

http://streetfightercafe.info/XJ_page.html

Not a source for restoration... 8O ... but it may help for a modified. Being added to / revised daily.....550/600s have a track history, parts interchangeability between models and availability of reasonably priced spares ( ebay) second only to Oil cooled GSXRs (IMO)...ya just have to dig & look around..

 

Thanks for the info amigo, I'll take it easy on the exhaust for sure. Good thing I have a complete parts bike! Shoot, I guess I only get 2 tries! HAHHA! Thanks for the link. I'm pretty excited. I've wanted an XJ for a while and couldn't pass this up.

 

Awesome score man, I am also in the middle of tear down on my 81' 550. I will get a build thread as soon as I can figure how to post pics... any advice??

 

Yes. Take lots of pics and if you don't already, go buy some on blaster!

 

You're gonna need it for all those rusty bolts!

 

Welcome! I think you found me over on the Iconmotosports forum as well friend. Good luck with the build! As for the mufflers just yank on those bad boys a lot of times they become rusted in the collector. For direction I'm a big fan of the rat so the first black one is definitely what I prefer but to each their own - that's what I love about these bikes. Good luck and keep us updated.

 

Also my biggest suggestion would be to take a day or two and really search the entire forum using keywords for any questions you have - that helped me a lot of times before asking I'd look around more than likely there are about 5 threads with answers....just don't ask about PODs...that always gets interesting...search that one first for sure haha.

 

Sounds good amigo, I've been going all through them, there is a lot of good info here. I think I did find you on the icon forum. Nice bike amigo!

 

I'll take those highway pegs off of your hands if you're selling them still. I just want the pegs I have the crash bars already. Shoot me a price...has to ship to 08330.

 

As of right now the pegs are spoken for amigo. I'll pm you, etc. I'm going to try to get some pics up tonight for some of the parts I've removed and are still available. Thanks for looking amigo.

 

Ok amigos! As promised, I took some pics of the parts i pulled off this weekend and made a thread. Let me know if there is anything you're interested in. I also have that spare bike so if you're looking for something I haven't taken off yet, let me know! Thanks for looking amigos. I'll update as things are sold as well.

Here's the thread!
http://xjbikes.com/Forums/viewtopic/p=2 ... tml#292294

Didn't get to work on my bike tonight as the gf had me painting! UGH! I hate painting walls!

 

I'm right with you on painting...now I know why all of the union painters are so shot out... from the fumes and monotony.

 

Ok quick, very small update. I need some info before I proceed on this. Pulled the top triple clamp off. I plan on putting clip-ons on the bike instead of the bars. So I was thinking, couldn't I just shave down all that excess material on the top triple clamp?

The red lines sort of indicate what I'm thinking of removing.





Of course it won't be completely flat, but a much lower profile to work with that's for sure.

Here's a couple more pics of the top clamp for reference.







I've still got the clamp on the parts bike too, so if I screw it up, I can always revert.

Opinions? Advice? Help? I want to get this sorted before I go forward with the bars, etc. Thanks in advance amigos!

 

hack 'em off and grind away. I'd recommend a bench grinder with a course wheel to start then finish with an angle grinder with a smoother wheel and then sand with different grits and finally polish or paint!

 

You can cut the of then use a 40 grit flap wheel in your 4.5" grinder to good effect.
Thats how I did my top yoke. Polish it up with smoother grade wet/dry paper to finalise the polished look.
Checkout the Scottish cafe racer thread to see how it will turn out.

Cheers
Col

 

not 100% positive on this but isnt the bottom portion on the clamp hollow. Wouldnt cutting it leave a hole in the center of the remaining portion not cut off?