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1981 Maxim XJ 650 restore project

Discussion in 'XJ Technical Chat' started by Glen F., May 13, 2019.

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  1. Glen F.

    Glen F. Active Member

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    Any ideas as to where I can pick up throttle shaft seals?
     
    Glen F., May 31, 2019
    #41
  2. Cattleman XJ

    Cattleman XJ Member

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    @chacal for all your XJ needs
     
    Cattleman XJ, May 31, 2019
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  3. Chitwood

    Chitwood Well-Known Member

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    Go for a full out deluxe rebuild kit if you can swing it. Very nice to have everything right there to replace.
     
    Chitwood, May 31, 2019
    #43
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  4. Glen F.

    Glen F. Active Member

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    Put the carbs back on the bike, but I haven't cleaned the gunk out of the tank yet. Is there a way I can get gas to the carbs without the tank hooked up? Just want to test things.
     
    Glen F., Jun 13, 2019
    #44
  5. k-moe

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

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    You can either buy or make a remote fuel tank. You can also just fill the carbs using a 2-stroke mixing syringe and squirt fuel into the fuel line on the carbs.
    I make my tanks from old steel lawnmower fuel tanks, but most anything that can safely hold fuel will do.

    This thread has plenty of ideas. Pay attention to my post on page 2 (well...pay attention to all of the posts, but tht one in particular, because safety).
    homemade-aux-fuel-tank.41309
     
    Last edited: Jun 13, 2019
    k-moe, Jun 13, 2019
    #45
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  6. Glen F.

    Glen F. Active Member

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    Hooked up a makeshift gas tank made of a coffee can and brass fittings. The bike started, but reved like crazy. Shut it off right away. What would make it rev like that?
     
    Glen F., Jun 16, 2019
    #46
  7. XJ550H

    XJ550H Well-Known Member Premium Member

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    first thing to check is the choke and throttle cables reversed on carbs.
    did you shut off choke when bike starts running away that's what the choke does as bike warms up or if bike is warm enough.

    check throttle cable adjustment and that cable is sitting fully in cup and linkage is not binding.

    turn down idle knob rear of carbs


    this link shows carbs throttle linkage middle of carb outter bracket clamp style is choke
    https://www.xjbikes.com/forums/threads/owww-my-eyes.112790/
     
    XJ550H, Jun 16, 2019
    #47
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  8. Glen F.

    Glen F. Active Member

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    I feel so dumb. Forgot to put the air cleaner and cover back on. I'll try and start the bike again tomorrow.
     
    Glen F., Jun 18, 2019
    #48
  9. k-moe

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

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    Shouldn't rev high with the filter removed if everything else is OK.
    That will lean the fuel mixture out, but not enough to keep it from holding an idle.
     
    k-moe, Jun 18, 2019
    #49
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  10. Glen F.

    Glen F. Active Member

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    I took the cover off the front brake reservoir, to find everything crystallized. Is there any way to clean that before I replace the brake lines and brakes?
     
    Glen F., Jun 25, 2019
    #50
  11. k-moe

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

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    HOW TO: Rebuild Your Master Cylinder

    Rebuild the calipers too. They will be just as bad.
     
    k-moe, Jun 25, 2019
    #51
  12. Glen F.

    Glen F. Active Member

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    I looked at the haynes book, and turns out I had the choke and throttle cables backwards. Changed them and it ran great. Slaps forehead open palm.
     
    Glen F., Jun 26, 2019
    #52
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  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    your welcome. always check the simple things first
     
    XJ550H, Jun 26, 2019
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  14. k-moe

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

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    We've all done it at least once.
     
    k-moe, Jun 26, 2019
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  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    maybe twice
     
    XJ550H, Jun 26, 2019
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  16. Glen F.

    Glen F. Active Member

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    I took the master cylinder off. All crusty and dried out. Cleaned it up a bit, but one of the two holes in the cylinder doesn't seem to be drilled right through. Is this normal? I thought one was for a return. Going to pick up some brake cleaner and clean it up good. The piston boot and seals are still very soft.
     
    Glen F., Jul 19, 2019
    #56
  17. firebane

    firebane Active Member

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    They just magically fit in either spot!
     
    firebane, Jul 19, 2019
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  18. Glen F.

    Glen F. Active Member

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    I should have said in the reservoir.
     
    Glen F., Jul 19, 2019
    #58
  19. Glen F.

    Glen F. Active Member

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    Master cylinder all cleaned up. Sight glass is a bit swollen. I'll replace it another day. Trying to remove the front tire today. Took out the cotter pin, took off the nut, loosened the pinch bolt and took off the caliper and speedo cable, but I can't get the axel out. Tried to smack the threaded end with a block of wood and a mallet, but it's in there good. Any helpful ideas out there?
     
    Glen F., Jul 27, 2019
    #59
  20. XJ550H

    XJ550H Well-Known Member Premium Member

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    c
     
    XJ550H, Jul 27, 2019
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