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Test setup

Discussion in 'XJ DIY How-To Instructions' started by Jack Miller, Feb 2, 2017.

  1. Jack Miller

    Jack Miller Member

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    I just purchased what the owner said was a low mileage XJ550 engine and would like to set up a jig to test run it before yanking the engine out of my higher mileage almost runner (runs but doesn't idle). Besides coil, CDI and battery, are there any other external components will I need and what is the bare minimum electrical connections will I need to make?
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    minimal wiring diagram eQNlgxq.jpg m1csRY7.jpg
     
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  3. XJ550H

    XJ550H Well-Known Member Premium Member

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    have you tested high milage motor ?
    compression, valves ect...
     
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  4. Toomanybikes

    Toomanybikes Well-Known Member

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    What do you consider high mileage?
    I have an 84 xj750rl with 99,000 kilometres on it and it runs great
     
  5. Jack Miller

    Jack Miller Member

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    I haven't been on in a while. Thanks for the chart. Now on to the questions. Motor in the bike has about 50K miles on it (Without going out in the cold to check) Compression is good. I cleaned and rebuilt the carbs with new needle and seats, paying special attention to the pilot circuit, put new manifold boots and new spark plugs. The choke/start circuit was frozen in place but I got it freed up by wiggling it back and forth. I read somewhere not to take the carbs apart because it is very hard to get them back so everything still works smoothly so I didn't take the chokes out and inspect them. It is leaking oil around the sprocket shaft which leaks down onto the crossover box and smokes a lot. That's a $10 part, so no biggy there. I bought the thing at an auction for $100. so I don't have a lot invested yet. I painted the tank and side covers this winter after stripping down to bare metal/plastic. I found another set of carbs for cheap and thought I'd clean them up and try that. The real reason I bought the spare engine was that I got it for $40 and just seemed like too good a deal to resist. I find myself doing dumb stuff like that on occasion. I've got three other running bikes and a shed full of Yamaha Enduro part bikes DT 125 175 and 250. Just can't resist a good deal.
     
  6. k-moe

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

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    Runs but doesn't idle. Didn't break the rack. These things are connected.
    It is not hard to get them back in working order once broken down. If you can do one carb, you can do four.

    Build test stand if you want, but you don't need a spare engine (though a $40 engine should never be passed up); you need to rebuild the carbs properly.
    IN THE CHURCH OF CLEAN
     
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