XJ650H RESURRECTION "Eddie"

Hi my name is Robert and I live in lower mi. This is my first motorcycle. I purchased it in 2001 for $750 sight unseen to help a family member.
it's condition was worse then bad as it had bee stored under a wood pile
for more then a year.

I stripped out everything intending on rebuild however
The opportunity became lost and the bike
Ended up tarped outside for ten years.

after removal of all unuseable junk i am left with the following
frame (with rust and some pitting nothing too bad)
coomplete engine and final drive
both tires
alot of hardware all rusted

It has to be this bike, the first motorcycle I ride has to be the one that spent ten years looking into my room from outside.
Simply no other bike will do. Or deserves a second chance
This bike has had many po and they all sucked I don't want to be another another or it's last.
This bike is an 82 xj650H the engine has been swapped with an 750 that looks like it was peicemaild together.

 

welcome blue, I understand your feelings about the bike.
If it was me Id diagnose the engines condition with a compression test.
and maybe get some decent artist brushes and get at it with some rust reform. Before putting too much money in that plant we need to find out what it's health is. can you post a few pics to see what we are working with?
There is lots to do but lets take it one thing at a time.

 

on second thought if it sat outside for years you may have rust in the rings and turning it could be bad, maybe pull the plugs and put some oil or mmo in there for a few days first, and roll it by hand before turning it with the starter, just put the plugs back in so the holes aren't open to the elements.
others will be along shortly with some more ideas too.

 

I have alot of experience in restoration though its mainly in historacle aircraft.

List of things I have to do
Catalog all the parts I have and can use
Purchase a factory manual and userhandbook

Create a masterlist of all the parts that go on the bike in my own format
Identify all parts missing and source each accordingly

Creat a build plan for each section of the bike

question: should i make a blog here and add/catalog all the work i do on this bike.

 

thats a good idea really, and you seem method minded, that bike will be on the road before you know it, now if you can add some pics or a "walk around" video or something, maybe keep that updated as well you would have a great build blog running. just my opinion

 

Welcome to the site Bluemister!

You took the first step in making this happen by coming here. You're attitude then and now is absolutely correct. You did the right thing helping out years ago and you can do it again. There are several ways to remove and eliminate the rust and oxidation. Everything else that needs to be done is just one step at a time. You will not want to use those tires if they are that old.

These bikes are seriously underrated and under-collected, but all of us here know what great machines they are! They are worthy of restoration. Skw1972 is right about your starting point, get a battery and test the compression, be careful if your head is dirty not to let anything down the hole. Keep us informed!

 

yes there is rust and debrie in all four cylenders and the cams and cam chain have rust as well
the bike is safely in side a garage and i have sprayed everything thats rustable with a teflon oil i use on all my projects.

Im still waiting on the factory manual before i get into the engine i promise to be a prolific picture poster it will be in my gallery

 

BTW I should mention that this bike is mainly just a frame an engine and about 10% of the smaller components if you havent seen my gallery.

 

Just noticed that you have restored airplanes. I look forward to your work on the XJ, and I have no doubt it will be very nice. Understanding the complete nature of an airplane and how critical functionality is will serve you well when it comes to 2 wheels. Post on!

Not complete by any means, that's true. Working in your favor (although I can't be 100% sure about this) is that the 650's were very prolific in sales/manufacturing. At least I have seen many more of them for sale and on here than the other models. Some parts are unobtanium as NOS or Aftermarket, but can be found if you look long and hard enough. Most of what you will likely need is easily available. Check out the XJ4Ever catalog listed on this site (top right link).

P.S. You will win many friends here with pics and restoration.

 

The stamp on the engine is 15R meaning it is from an 750J this site is cool in short order i have decoded my vin and the engines vin and learned alot

 

ahh. the force is strong with this one
I look forward to this one.
Many of the things that are normally required for a project like this you seem to have a firm grasp of. I get the sense you followed within the forum and did some home work before joining, that along with your past project experiences will move along much smoother.
I also sense you are aware of the "safety" issues that will need to be addressed? bearings, brakes, controls, tires, etc.?
Finally I more than respect the reason it has to be THIS bike.

 

Restoration logs and journal here

I started a blog here to better document keep the information formatted

 

Welcome.

Damn near brought a tear to my eye to hear that a sadly
neglected xj might have a chance to live again.

Good luck and keep us posted.

 

Welcome to the site. Can't wait to follow this one.

 

Welcome, Blue!

 

Hellooo
I'm excited about your enthusiasm. I'd love to see where this bike goes. Keep us informed. We can help immensely

 

never give up man!! cant wait to see! knowing that you restore aircraft means you might be meticulous. awesome.

 

OK for todays good news
I made an atachment to vacume out all the debrie from a cardboard tube
and removed as much from the header. I rebolted down the header and
added oil directly into the cylenders and crankcase (5w10 syn I know but i have alot to waste will use real motorcycle oil) and removed the left side oil pump and turned the engine ccw i only encountered two rough spots
and it turned smooth after that.
The next step will be to remove the cam chain and inspect the cylenders
directly.

Note: I took pictures and they will be in my gallery tommarow
I also noticed that most of the case screws on the engine are head stripped.
I used PB Buster to loosen and tapped it they came right out with enough
perpendicular pressure.

 

just a thought but you may gain much benefit from ordering some KROIL.
that stuff will free anything. PB is good, I use it alot, but Kroil is a wonder of mankind, I've never seen anything like it.
Great progress! Be very careful with the carb to engine boot/manifold screws.
some Kroil and maybe a little thermal cycling should do the trick, at least it did for me.
once I got them out I got new ones from lowes in the hardware isle. Same for the exhaust collar bolts. (and various others)

 

I hadn't thought of that thankyou they do need
To go for now a very easy break means a very bad
Fix. It's an insane procedure to remove steel screws
From aluminum.
On a bad note the exhaust is rusted through
After the down pipes meet the 4 into 2 right side is bad
Left not so bad

 

Ive seen a few of those on ebay and there are aways bikes getting parted out here as well, also when guys go with 4 into 1 systems the old exhaust becomes available.
Im sure as the project continues we'll be able to get what you need.
I really like the way you are handling this project, you will be rewarded with a fine machine in the end and you are picking up fans and friends as go.
You may be setting a new standard to proper xj refurb procedure.

 

the hardest part is deciding where to start lol