Motorcycle enthusiast/ currently working on a project!

Hey! Name's Michael from Miami, FL!

Working on my 1982 XJ 550 Maxim I bought about 3 months back that doesn't run and finally got the chance to add some pics of the project. I'm going to start using this thread as a progress keeper from now on! Future plans: Cafe Racer.

Any advice would be greatly appreciated!

Upgraded some parts because they were out of shape.//considering creating a simple,custom wire harness

Upgraded parts thus far:
-K&N air filters
-New spark plugs
-Gravity fed modern petcock
-Clubman Handle bars
-New Starter Solenoid

*stripped most of her down to better analyze everything on the bike; I like to know what I'm working on.*

Known issues:
-Starter button doesn't operate.~I've switched the controls, switched the solenoid, cleaned the connections, checked the wires closest to the plug, still no reaction. Thinking it's the relay.
-can't figure out where to lead that air hose coming from the crankcase
-need to rebuild master cylinder

 

That clutch assembly has me iffy >.<

 

Neeeeeed to clean out that crank case

 

These carb boots have me worried

 

Update *

Ordered new starter brushes because the starter wouldn't turn over anymore.

 

When I got it, this plug was never connected, though I have the correct solenoid connection.

 

The clutch arm return spring appears to be missing. Check the safety circuit. That could be why you are getting nothing from the start button if you have a fully charged battery. Before you do any more modifications, get her running. Those carb boots look bad. How do they look from the inside? If the inside is cracked too, replace them. You will probably need to replace them soon anyways. That plug in the last picture goes to the sidestand switch if one the wires is blue/yellow stripe and the other all black. This could also cause your starting problem.

 

you also need a throttle shaft seal, plastic washer and an "e" clip. those air filters will cause you all kinds of jetting woes too. you really should verify that you have good compression on all 4 cylinders before you spend any more money on that bike.

FU

 

The previous owner decided to chop off the wire from the oil filter/ side stand safety so I figure this could've also contributed to my dilemma? And I'm going to try the compression test as soon as I have the rebuild kit for the starter because it started failing.

 

Here's the link brother http://www.knfilters.com/mobile/mPr...clid=CjwKEAiAi52mBRDkq5bX0vq1-RQSJAAq_7IGvZae

 

Ahhh that makes sense I'll check it out as soon as I get home! Also, regarding the choke, where should I keep it set when attempting to start the bike after I rebuild the starter? And is it possible to show me exactly how the clutch return spring would look when added so I have a better idea as to how it goes?

 

When you say your starter " started failing" does that mean that it is trying to spin?

 

Yes. I listened to the starter as much as I could and it mumbles but doesn't make a full rotation

 

I could almost GUARANTEE that the starter has been bad from the beginning, never paid much attention to it and it almost bit my arm off.
*facepalm*

 

The more pictures you post, the more opportunities I can see for you to become the best XJ mechanic ever!

Hope you didn't pay a lot for the bike; looks like the PO did quite a number on it.
Don't loose your enthusiasm . . . .

I recommend you start with pulling the carb rack and going to Church on it.
http://xjbikes.com/forums/index.php?threads/in-the-church-of-clean.14692/

Starter brush replacement (how did the o-ring seal in the picture above get so discombobulated?)
http://www.xj4ever.com/starter brush replacement.pdf

Brakes, brake lines, master cylinder, new tires, Petcock, control cables, fork seals, and rear shocks are probably all in your future. Plan on investing at least $800 in parts.


Parts?
Go to XJ4Ever (upper right hand corner of web page)

 

I didn't pay much! It looked like it was in good shape but hey I guess we learn out of mistakes huh. Seeing as this bike is pretty reliable and is loved pretty dearly by many people on this site I figure it should be a worthwhile fix. /
The o ring... Ahh the o ring... I have absolutely no idea how an o ring could become that rattled up especially since it's in an enclosed area. I'll get started on the starter as soon as possible. Also, regarding the carbs. I have new pod(whatever you'd like to call them) installed but with the stock jets in the carbs. Any idea as to which size jets I need to purchase before cleaning out the carbs(waiting on my budget to be able to afford new boots)?

 

I found these gremlins (including two more under these three) soldered together(PO). Going to check out the wiring diagram as soon as I get home / unless someone knows by heart where these wires go. Looks like a mess

 

Looks like what comes off the main key switch......Big Red comes from the fusebox MAIN fuse, brown goes back to the fusebox and then splits into three separate wires, each one powering the other circuits (Lights, Ignition, Signals) in the fusebox, and the blue powers the rear tail light/brake light circuit.

This connector/wires should be somewhere up near the front of the bike, hard to tell the position from the angle of the picture.....


P.S. the orange and red/white stripe wire is the power feed to the left side (plugs # 1 and #4) ignition coil.

 

Taping the wiring temporarily ASAP

 

can you snap me a pic of what it looks like? I can't find it

 

if I'm

they look to be power from ignition switch aand the other 2 are two your coils

 

From the XJ DIY How-to-Instructions:

http://www.xjbikes.com/forums/index...-101-part-1-the-400-550-600s-with-pics.29541/

Scroll down to the last pic form Bigfitz52 and you can see the return spring at the bottom of the photo.

 

Huh? This one suprise me. Now, now, Stump...we want to encourage our fellow members but you were on the old site. Just about anything within function that can be done to a xj has been done. From rear wheel to front, soft tail to hard, dual to mono shocked, complete front end swap, mill swap, frame refab, trikes, fuel injected; you name it and its probably been done. Not to mention all the meticulous stock xj's. He has a nice build going but the best ever is a stretch. I honestly don't think there is a best. There's too many that are just that good; both stock and moded. I miss the gallery.

Gary H.

 

I have seen most of them and have gained inspiration to go harder on this project. I really appreciate the push rocs! Waiting on the starter motor rebuild kit to come in still :/

 

Yeah I see the little impression it's supposed to go in. I'll look for the piece soon

 

Do you think this could be the issue? Maybe splice a fresh piece in between?

 

WOOO it came in, I'll get it installed soon enough(studying for tests)

 

Crooked screw is harder than I though

 

Wish me luck, brothers.

 

Yikes! That is the soft, dirty underbelly of a starter motor, no doubt..........

 

if you haven't found this thread yet, it might help.

http://xjbikes.com/forums/index.php?threads/replacing-your-starter-motor-brushes-w-pics.45727/

FU

 

Oh my !

 

Glad I'm not the only one surprised haha. Well, I'll post some pics of the progress right now. For some reason now it's really hard to spin after the rebuild, any ideas why?

 

Close up of one of my little culprits >.>

 

I believe the main problem is the rebuild kit's replacement baring... It didn't spin as smoothly as the original (Really hard to spin)

 

I believe spinning the starter by hand at the shaft end should feel tough to turn. I remember reading it somewhere on here. I think its because the mechanical advantage is fighting against you in that case (don't quote me on it)

 

It's barely even turning now though, I have to really force it. I did remove this rattled up tape from the inside of the starter where I THINK the actuator's arm was making contact with in order to stop it from touching the metal shell

 

Have you tried hooking it up to power to see if it spins?

 

Yeah. It just sparks as if there was a short but I made sure no metal pieces inside were touching the frame.

 

From the starter How to Guide, this part is sometimes overlooked and is very important.

":::::::::::::::NOTE::::::::::
When re-installing the battery cable to the starter, be absolutely sure that the "bolt holder" is not cracked, and be sure to use the o-ring and felt washers upon assembly. If this bolt is not well insulated it will cause a ground fault and the starter will not spin, nor will you be able to bump start the bike."

This is referring to the stud that connects to one of the brushes and exits the starter. The large cable from the solenoid (POS) is eventually secured to the stud. The stud must have all the components installed correctly to insulate it from the starter chassis.

 

Just wait til you get into the carbs!!! Take a look at my "before/after" thread to get a sneak-peak at what you might be in for...........

There WILL be substantial drag when trying to turn the starter by hand. That's the way they are. But if all you're geting is sparks, then yeah--something's still not right.

Where did you get your parts from?
Len-I bet the problem isn't the replacement part
Some other company - I bet the parts are wrong

dave

 

He could've done what rooster has said, and cracked the insulator boot for the terminal post. I know I did it my first time haha gotta be careful tightening it

 

http://www.ebay.com/itm/271502671433?_trksid=p2059210.m2749.l2649&ssPageName=STRK:MEBIDX:IT
Here's where I ordered it from

 

I don't seem to have any cracks, I do recall removing this worn out tape (Maybe insulator) From inside when I was cleaning it out

 

Then I will stand with what I said about the parts until proven otherwise.

Dave