2014 XJ 650 RETRO BUILD

Well after 3 years working on this $400 craigslist project 20 minutes here 20 minutes there its finally all finish from tires to new seat its all done. i did everything myself. I would have to say the hardest thing was removing the old anaconda of wires in it, I kept trying to repair wires, repair connectors that i just ended up getting tired so I decided replaced every wire, I got a new fuse box and went to work! I went with a siemple wiring of the xj. It took some time to figure out how to start it, It ended up being a bad neutral switch, i had to remove the engine to replace the switch so i took extra time and cleaned it and painted everything in black, carburators were taking out and deep cleaned and painted silver. The tires I ended up putting my self too I taped and kept the original silver trim everything else went black. The tank is a small one but am only doing really short trips so 2 gallons is ok with me. here is a list of things i did.

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* new front and rear tires
* new straight bar handles
* new grips
* new start relay
* new filter pods
* new air vent filter
* new seat
* new tail lights
* new rear shocks
* new exhaust wrap
* new 1.8 gas tank
* new gas filter
* new headlight (fog lights)
* new tach
* new universal start single push switch
* new two fork seals
* new mud guard
* new fuse box
* all new simple wiring harness
* tons of painters tape and black spray paint (follow instruccions)

 

I must be missing something.

I don't see "checked and adjusted valve clearances" "wet-set float levels" "vacuum sync'ed carbs" or "rebuilt 30-year old brakes" anywhere on the list.

Looks like nothing but cosmetics from here...

 

That tank is tiny!

 

Yeah looks like I missed something.

I didnt checked and adjusted valve clearances I did set float levels but no vacuum sync'ed carbs am ordering a tool soon. And no break rebuilt just new pads and used break control from newer bike I don't see why replace break lines they don't leak or cause problems.

Looks like nothing but cosmetics
And I think it looks nice. I don't see why break the engine open when is running good but good idea wizard maybe next owner after am done with it.
Tank is small but am getting to work and home just fine.

 

Why replace break lines: http://xjbikes.com/Forums/viewtopic/t=41400.html

You "break the engine open" to check the valve clearances because it is a vital bit of maintenance that can mean the difference between a healthy motor and a blown-up one. It's required maintenance, just like oil changes; doesn't involve a major tear-down.

There is more to recommissioning an old motorcycle than just how it looks, if you actually plan to RIDE it. Thirty year old brakes are dangerous. And if you're going to put more than 5000 miles on it, you'll need to learn how to adjust the valves and sync the carbs.

All you've done so far is "gussy it up." Get some of the actual mechanical work done and we'll be impressed.

 

I love it, some of the details look like what I'm after for my bike, like the engine colours, pipe wrap, front forks, minimal top end.

That said, fitz is spot on, you gotta check them clearances.
Its a rubber gasket so re-usable, you cant really do anything wrong unless you do it at night, on the street, drunk and with the wrong tools.

checking the brakes thoroughly is only ever going to be a good idea.

I'm struggling with my licence plate tho, where are you putting yours?

 

My license plate will be on the rear fender. Two small screws holding the tag cover by a 4inch LED white light. It should work good. The breaks have new pads new reservoir. Old lines but work good.

 

30 year old brake lines that were only rated for 4 years. its your life vs about $100 bucks.

 

ok i have to ask the brake line preachers one thing.
how old are the rubber brake lines on your car ?
let the excuses begin

 

My lines are all steel with bronze fittings

 

The flexible lines on my car aren't exposed to UV rays every time the vehicle is pulled out of the garage. Even so, they get replaced when it comes time to rebuild the calipers.

 

No, it's a good point.

A better question might be: "anybody ever had one pop?"

I have. Once on a '93 GMC Sonoma pickup; once on a Honda Nighthawk that was around 12 years old at the time.

Scary enough to not want to ever repeat the experience.

 

I had one pop on a 82 dodge rampage I had when I was 19. I spun it into a guardrail in the rain. I must've been braking at impact so it busted one of the lines. I had a little pedal if I pumped it but it would then go straight to the floor.
Luckily it was a 5 speed and late at night in the sticks so I was able to make it home by downshifting and the handbrake.

Don't think I'd want to experience it on a bike tho. Wouldn't want to have to rely on the rear brake to bring me to a stop from highway speed. Especially if you haven't checked/replaced the rear brake shoes!

 

never had one pop on a car. but I saw a few on vw beetles that swelled shut inside. you could apply the brakes but the one with the swollen shut hose wouldn't release.

CN

 

those are all real good answers but their for some other question.
hint, the answer is a number

 

Two and a half years old. Replaced every time the pads are done. Only takes one time having one rupture while trying to stop a 45 foot trailer.

 

Braided S / Steel outer. with a PTFE inner lining are guaranteed FOREVER.

 

Had a rubber hose on my Sportster pop a year after I got it. Thankfully, I was pulling out of the driveway at 5-ish mph when it happened.

At speed, it would have sucked some serious ass.

 

hi,

Really nice bike you`ve got there !

got some bigger pics, can`t quite see the details

Thanks