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81 xj650 build - handlebar controls

Discussion in 'XJ DIY How-To Instructions' started by Soakedinoil, Oct 19, 2015.

  1. Soakedinoil

    Soakedinoil New Member

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    Hey guys! Just recently purchased my 81 xj650 bike project for a killer $340! I put some new 28" drag bars on it and would like to change out the controls as there is limited space on these new bars. I plan on re-wiring the starter button as it already has an aftermarket button on it (Which broke) so I will be installing a new one off the bars anyways. This is going to be a clean cut build and I'm looking for some aftermarket controls to put on the bike. (Clutch lever, brake lever, throttle, etc). I was wondering if any of you have done this already and where I can find these parts. I've searched everywhere and haven't come up with much. Any help is appreciated! Thanks guys!

    You can also find the build on youtube, starting a new channel "Soaked In Oil" look it up!
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    after market basic controls try ebay. there are some cool push buttons out there you drill a hole in the bars and they push in. you can set them up wtih relays for head light or direct for horn and starter

    are you going with minimal wiring? these are from other posts
    eQNlgxq.jpg
    m1csRY7.jpg
     
    Last edited: Oct 19, 2015
  3. Soakedinoil

    Soakedinoil New Member

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    I'd like to go with minimal wiring while keeping the directionals but I'm not that confident in my electrical abilities yet. I've done some wiring myself but I don't know if stripping out the unnecessary parts of the loom is something I could do myself.
     
    willmarmnxj650 likes this.
  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    you would/could build your own harness.
    think small, you want to relocate your starter switch, you are going to run new wires from solenoid to switch then ground.
    your start point and end point is defined by component location, solinoid and ground.
    your choice is where the button goes
     
  5. Soakedinoil

    Soakedinoil New Member

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    Yeah I know how to do that. I was looking more for where to find aftermarket throttle, clutch, and brake lever assemblies in order to delete the clunky stock ones in order to clear up some space on the bars. The only ones I've been able to find were universal and I couldn't find a good write up anywhere. Thanks for the replies though, I appreciate all the help I can get.
     
  6. Soakedinoil

    Soakedinoil New Member

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  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    from compatibility chart on your ebay selection
    This part is not compatible with 1981 Yamaha XJ650 Seca Turbo.
    This part is not compatible with 1981 Yamaha XJ650 Maxim.
    This part is not compatible with 1981 Yamaha XJ650L Midnight Maxim.
     
  8. XJ550H

    XJ550H Well-Known Member Premium Member

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  9. Soakedinoil

    Soakedinoil New Member

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    Does anyone see a reason these wouldn't work? This was the response I got when I asked the seller
     

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  10. XJ550H

    XJ550H Well-Known Member Premium Member

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    for a master cylinder you need at least a 14 mm bore thats the question you need to ask bore size
    XJ650 Maxim and Midnight Maxim North American models (single-disc): the cylinder body will have the size 14 (meaning a 14mm bore) and the word NISSIN cast into it along the rear face of the piston bore.
     
  11. XJ550H

    XJ550H Well-Known Member Premium Member

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    17 mm bore will work for you
     
  12. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    nice
     
  13. kakie

    kakie New Member

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    Hope you guys don't mind me tagging on to this post but will the wiring for most buttons and switches work with the XJ? I've been looking at kill switches and on/off switches and none of them explicitly say compatible for XJ but it seems to me if the voltage is correct and itll fit on your bar then its just a matter of finding and connecting the proper wires together right?
     
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  14. XJ550H

    XJ550H Well-Known Member Premium Member

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    the only switches you will see listed as compatible with XJ's would be oem switches.
    so if it fits the bar and is configured to do what you want, your good
     

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