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Xj650 with Xj750 front end/dual disc swap -- Air hose on forks

Discussion in 'XJ Technical Chat' started by xtmag, May 17, 2019.

  1. xtmag

    xtmag Member

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    Hi there gang,
    I am almost done with my dual disc setup on my 81 XJ650 maxim. Donor bike was the 82 XJ750 maxim.

    So the XJ750 had the forks with the airhose, I have everything mounted but cannot seem to get the airhose connected, it is almost like I need a longer one.
    Is a longer one a possibility? otherwise, what am I doing wrong?

    Thanks!
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    are you using the air joints? and have them on the proper side ?
    air joint.PNG
     
  3. k-moe

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

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    If it were mine I'd have new hose made. Air leaks are likely with a hose that old which has been removed.
     
  4. xtmag

    xtmag Member

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    Ok with some more thumb wrestling, I was able to get it on there. It was indeed pointing the right way.
    Thank you!
     
  5. xtmag

    xtmag Member

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    Ok so I was able wrestle this on but the tip where you fill it with air touches the tank.

    I have called around my area for getting a hose made but no one makes one that small.
    I need a longer one, any ideas?
     
  6. Toomanybikes

    Toomanybikes Well-Known Member

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    Hose should not be too short. Factory fork spacing is identical unless the ignition switch is in the way. You do have everything on the forward side of the forks?
     
  7. xtmag

    xtmag Member

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    It’s the correct length, it’s just that the air fill port touches my tank at full lock. There is not enough slack to turn the collars so it doesnt touch. If I had a few more inches I couldn’t make it work. This is a dual disc upgrade to my xj650 maxim 1981.
     
  8. Toomanybikes

    Toomanybikes Well-Known Member

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    Show us a picture. Maybe steering stop is damaged and allowing it to turn too far? Or the 750 has a wider stop?
     
  9. Polock

    Polock Well-Known Member

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    are the collars swapped left/right? the valve should be on the clutch lever side
     
  10. XJ550H

    XJ550H Well-Known Member Premium Member

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    ^+1 the air valve is on the left side at a 90 degree angle. parallel to the blinker stay
    air valve.jpg
     
    Last edited: Aug 20, 2019
  11. xtmag

    xtmag Member

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    0BBAB02B-CDBF-4728-86DB-EC680CE83A69.jpeg I turned my collar around and now there is a casting that bumps my tank.
    I think I will just plug all the holes and spin it around so that nothing touches.
    Been talking to chacal as well, he had a similar idea.
     
  12. Toomanybikes

    Toomanybikes Well-Known Member

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    That collar is upside down that lug should be on the inside
     
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  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    nolug.jpg
     
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  14. XJ550H

    XJ550H Well-Known Member Premium Member

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    I think you need the 750 triple tree
     
  15. xtmag

    xtmag Member

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    Ok upside down! I can deal with that, I’ll flip it.
    I still have the 750 triple tree but the upper piece will need some sort of adapter for the 650 bars right?
     
  16. Toomanybikes

    Toomanybikes Well-Known Member

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    The 650 upper clamp will work just fine just use the plastic spacer as seen in @XJ550H picture
     
    Last edited: Aug 21, 2019
  17. XJ550H

    XJ550H Well-Known Member Premium Member

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    the bars on the 82 750 unbolt and you can buy some risers to put on them.
     
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  18. xtmag

    xtmag Member

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    B984B970-47D1-4659-98A4-77356AD79031.jpeg Solved!
    I flipped the collars and added a 1/4 inch ID hose shoved on the existing hose and make a loop.
    Gives me a bit of extra room and most importantly, doesn’t hit the tank.
     
  19. k-moe

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

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    That hose setup is sketchy. Use fittings, or have a line made. As you have it now the outer hose will leak, and/or damage the original hose.
     
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