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XJ650 Handlebar swap

Discussion in 'XJ Modifications' started by SwIrv, Dec 4, 2018.

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  1. SwIrv

    SwIrv New Member

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    I recently purchased a new Z-bar style handlebar, but I came across a thread saying I would need a different kind of master cylinder set up. Can anyone help me out?
     
  2. jayrodoh

    jayrodoh YimYam

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    I did this write up, different bars but same idea. You really won't know until you mount the bars and MC if it is the wrong angle. I don't know what year yours is but if its a pre-82 Maxim, the starter button is grounded through the bars. If you got painted bars, you'll need to remove some paint at the clamp and where the switch housing is or run a ground wire up to keep it working.

    https://www.xjbikes.com/forums/threads/handlebar-swap-ditching-the-horns.94195/
     
  3. 50gary

    50gary Active Member

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    Have you tried the original M/C on the new bars? It's likely the reason the old M/C may not be compatible because of the angle of the reservoir? That's only important when you open the cover for service, you would have to keep it level to avoid spillage? Or.. the grip area of the new bars may be too short to mount the all in one M/C and reservoir? Just some thoughts without pictures to go by?
    Cheers, 50gary
     
  4. SwIrv

    SwIrv New Member

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    So, the handlebars are somewhere in the house but the wife got to the delivery before I did and she is holding on to it whereabouts until my birthday next week. The original M/C was damaged by the P/O hence me having to get a new one.

    Jayrodoh & 50gary – The bike is a 1981 xj650 (Model G I think) maxim, in your post it said that the M/C has to be parallel with the handlebar, does it matter if my handlebar dips toward the ground or up at an angle? Below are photos of the handlebars I got.

    handlebar.JPG handlebar2.JPG
     
  5. jayrodoh

    jayrodoh YimYam

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    You'll want it relatively parallel to ground or level when installed and the bike is sitting upright i.e. riding position or on center stand. This allows for easier maintenance and eliminates the risk of getting air in your line should you lean into a turn and the fluid goes to one side of the reservoir because it is already on a tilt because of the installation. A master cylinder will function just fine on an angle, you just need to make sure that the holes in the bottom of the reservoir never get exposed while riding, the more level the MC is the easier this is to accomplish.
     
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  6. Chitwood

    Chitwood Well-Known Member

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    My budget didn't allow me to purchase a more "flat" MC when I modified my handlebars so I kept the angled one that I was using on the buckhorn bars. I keep it full enough so in a full lean the ports never can catch any air. If they do, I have more to worry about than my brake system as I'm likely strewn about the road somewhere. I did upgrade to SS braided lines over the original rubber lines which gave a much better feel to the lever, in my opinion.
     

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