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Winter Rebuild Questions - 83 750 Maxim

Discussion in 'XJ Technical Chat' started by Hamster, Feb 13, 2014.

  1. Hamster

    Hamster Member

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    I am going to run a series of questions here as I tear down my Maxim this winter. The bike runs like a champ and has been great save a few of the usual problems of age, which have been resolved. The big one that remains is that there is some noticeable rust on multiple frame welds. So, I'm going in pretty deep and expect to do a whole bunch of stuff while the bike is indoors and stripped down.

    Three questions to get it started:

    1 - I want to lean forward just a little more and I want to lose the buckhorns. I intend to build up the foam on the front half of the seat and want some bars that are a little straighter and a little lower. Candidates might be Bikemaster Daytona, GP Touring, or Superbike, for instance. I am wondering if anyone has done something similar AND found a bar that didn't require replacing the master cylinder? Or is it sloping a little not such a big deal?

    2 - I might do a bunch of cosmetic stuff, but it's a lower priority than reliability, safety and budget. To that end, of the various side cover gaskets on the motor, which can I expect to be re-usable and which can I expect to have to replace? I am pretty inspired by all the beautiful polished aluminum I see on this site. Also, the side covers with the Maxim emblems are quite dulled. They are plastic AND aluminum? Any tips on restoring those?

    3 - I would love suggestions of what else I should consider doing while I'm in this deep. I already updated the brakes, overhauled the carbs, fluids, rubber, battery, and have done various typical maintenance tasks. My main objectives are to address rust/paint on the frame and swing arm; clean (renew if nec) all electrical connections; change fluids; valves; tune/synch/mix/synch; swing arm bearings and install the same insanely bright LED taillight that I put on my DR350.

    Got a break in the rain so I'm off to pull the tank and carbs so it can come inside. Thanks for any answers.

    A couple "before" pix:
    http://s1316.photobucket.com/user/remse ... 7.jpg.html
    http://s1316.photobucket.com/user/remse ... 1.jpg.html
     
  2. Polock

    Polock Well-Known Member

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    Re: My Winter Refresh - 83 750 Maxim

    you could get some new grease in the steering stem bearings, lube your cables, take the pins out of your calipers and wipe some grease on those
     
  3. lacucaracha

    lacucaracha Member

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    Re: My Winter Refresh - 83 750 Maxim

    As far as the side cover gaskets, those aren't really replaceable. Using hi-temp gasket maker does work, if you prefer not to order them, but making sure the mating surfaces are spotless and flat is important. Follow the directions on the tube and you should be fine. Mind you, the front side covers over the crankshaft ends are not holding oil, and they have little pin holes which are supposed to be there, so mind that fact when using gasket maker.

    I've never had a gasket come of clean enough to re-use.
     
  4. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    I'm hoping you meant that the side cover gaskets aren't REUSABLE. They gotta be replaceable. If I'm going to pull them, I am going to replace them with the proper replacements. I guess what I'm wondering is: how many am I going to have to buy? Clutch cover, shifter cover, generator cover, oil pump and it's mate on the right. Maybe prettying up the motor is outside the budget. It is definitely the ugliest thing on the bike, after that lump on the seat.
     
  5. Polock

    Polock Well-Known Member

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    Re: My Winter Refresh - 83 750 Maxim

    you'll need the clutch and shifter for sure. alternator, you might get by with gasket maker and what's left of the old gasket. the ignition and it's mate on the other side can just get buttered up, no gasket, they just keep stuff out.
    there's a seal where the shift shaft comes thru the cover, get one, their cheap
     
  6. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    Thanks for the tip on the shift shaft seal, Polock. That all sounds like I can get away with stripping, and polishing without breaking the bank. Maybe even work repainting the tank into the budget.
     
  7. happydog500

    happydog500 Member

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    Re: My Winter Refresh - 83 750 Maxim

    Did you buy that rack that hangs off the back of the seat? How much and where?

    Chris.
     
  8. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    That rack came on my previous Maxim 650. It appears to have been made specifically for that bike and has a backrest that telescopes forward. It's a keeper, so I added a small piece on each side to adapt it to the 750. My 750 came with a rack that looks a bit cheaper and more universal, which I took off. I have that rack still if you might be interested in that one.
     
  9. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    Couple more questions as the rebuild progresses.

    1. I am using aircraft stripper on a bunch of the usual aluminum stuff. The clutch cover carries the oil level window. Will the stripper trash it? Is removing it REQUIRED? Is it glass or plastic?

    2. Inside the the shifter side cover are a couple of bits that look mostly harmless to remove for stripping of the clear coat. Two cheap gaskets is all that it takes but I don't see reference to pulling those anywhere. So, easy as it looks or maybe it's a fiasco waiting to be unleashed?

    3. Can anybody suggest an easy to find rattle can paint that they have used and found to match the frame and swing arm well? Mostly mine look too good to bother stripping and repainting. They just need a little prep and touch up, so a good match is, well, good.

    4. There is a damper through which the mufflers bolt to the passenger peg brackets. Mine are serviceable enough. But on just one side there was a trashed looking rubber washer against the inboard side of the damper. 5/8" ID maybe 1-1/4" OD. The fiche shows nothing. Can anybody confirm what should be there?

    The weather is just starting to get really nice and my bike is in many many pieces. Must resist the rush. Good thing the little 350 is solid.
     
  10. lacucaracha

    lacucaracha Member

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    Re: My Winter Refresh - 83 750 Maxim

    i can kinda answer number 1...

    The side cover is glass, so the stripper shouldn't affect IT, but the gasket may be affected.

    It's a rubber piece, and the stripper may not kill it right away, but could lead to an early failure down the road.

    As far as #2, what do you mean inside? I'm assuming you meant outside since stripping wouldn't mess with anything inside, or do you just want to remove it so it doesn't get messy?

    #3, The 750 may be different than the 650 but I doubt it. I used Dupli-color semi-gloss cheap stuff from o'reilly, and it looks pretty damn good on engine bits. Problem is, the frame has a clear coat and is glossy...

    The duplicolor is the same, or damn close to the combo switch housing color.

    #4 I think someone added that, ask Chacal about a replacement.
     
  11. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    Two more questions and a few pics.
    1. Alternator looks dirty where the brushes don't rub and polished where they do. Just leave it alone? Clean it up? How? I'm better with the straight mechanical stuff.
    2. The brushes show about 8.5mm are left above the wear line. The specs give a length (17mm IIRC) but don't say if that's total or above the wear line. Any deep wisdom there?
     

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  12. lacucaracha

    lacucaracha Member

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    Re: My Winter Refresh - 83 750 Maxim

    Alternator looks fine. You could use a bit of polishing compound to clean it up, or a neat trick is spending some time with a pencil eraser. It made mine look new after a bit of time.

    8.5mm after the wear line is still OK, that's what the line indicates. If you want to save the work later you could just replace them- they're cheap.
     
  13. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    Thanks for the reply. The shift cover is already off as I don't want to let stripper get on the upper half of the crankcase which looks painted and I want to go to town with the buffer. All the covers are off and gradually getting stripped for buff and polish. As are the fork lowers, peg brackets, and rear brake plate. Too bad the engine looks like . . . But that's for another winter.
     
  14. Hamster

    Hamster Member

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    Re: My Winter Refresh - 83 750 Maxim

    Couple questions and update pix:

    Just when I was thinking this thing was maybe gonna come out pretty nice, I choked. I used Blue Coral rubbing compound on the plastic part of a side cover. It is way dull. Suggestions Please. Paint for plastic? Take it to the drill press that pulled buffer duty? Leave it that way to punish myself for years to come?

    My wheels look fine. Little to do. But I'd like to shine up the bare spoke edges. They have pronounced machining marks. I like that. Anybody done anything really creative there?

    The cap over the breather on the final drive housing pretty much fell off under little duress. Looks like there is red RTV in there. Is that all that holds that thing on?
     

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  15. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Re: My Winter Refresh - 83 750 Maxim

    You can polish them up very nicely IF you know the "trick."

    And the trick's name is Dremel. If you use a Dremel (or similar) with the extension wand and a MINI buffing wheel, you can polish the spoke edges in the same direction as the machining marks. You have to be careful not to overdo it and "burn" the edges but if you're careful you can get the wheels polished up nicer than new.

    Also, something else you might want to know about: XJ4Ever now offers these (and I don't mean scruffy crankcase end covers:)

    [​IMG]
     
  16. SHOOTER

    SHOOTER Member

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    Was looking at this thread and wanted to let u know I put bike master Daytona bars on my xj750 and I love them. Everything stock bolted to them pretty nicely I think. Look at my gallery and u should be able to see them
     
  17. Hamster

    Hamster Member

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    Fitz, thanks for the tip. That is just what I will do to the wheels. My YICS emblems for the engine side covers are pretty good. Still need to figure out what to glue them on with though.

    Shooter, great pics with the Daytonas. That is exactly what I was aiming for and will order a set of those this week. Much appreciated. Are your mirrors still useful too?

    I'm still wondering what to glue to use for the breather cap on top of the final drive housing?

    And, I'm using Mothers Chrome polish on a bunch of stuff, but can I use it on the headers and/or mufflers?
     
  18. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    You don't use any glue on the breather cap. What you do is replace the breather. I read back and you state that there was RTV inside the cap. Some idiot PO stuck the cap back on with it; that isn't how they came from Yamaha. The breather cap is supposed to be held in place by a spot weld. You could get away with using a 2 part epoxy, but be careful; use too much and you'll plug the breather.
     
  19. Hamster

    Hamster Member

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    Should be on the road in a week or so. Latest question: has anybody worked out a simple clean way to eliminate the choke lever/cable? I'd be happy with a little lever right at the carbs. That's what my other bike has and it's no bother at all. And it cleans up the front end just a bit.
     

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  20. Hamster

    Hamster Member

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    [​IMG]

    Big night on the rebuild. Just gotta get enough of that Partida in a couple of guys to get this thing down from there, sync 'em outside, and maybe this rebuild rolls for the long weekend. Maybe.
     

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