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Simmy's Naked Turbo Project

Discussion in 'XJ Modifications' started by Simmy, Feb 25, 2017.

  1. Simmy

    Simmy Well-Known Member

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    I trimmed the sidecovers just enough to fit with the XJ900RK shocks.
    They are about 1/2" shorter than the standard XJ650RJ shocks. Combined with 16" XJ700N rear wheel this should lower the rear end about 1-1/4".
    A 16" FZ600 front wheel lowers the front just over an inch so this should balance out well.
    I'm going to run Bridgestone Battlax BT45 as they come in 110/90V-16 and 130/90V-16, the same sizes the Radian uses.
    I'm not sure about the finish on the pipes, it looks good upfront on the headers but too bright for the mufflers.
    I do plan to mount different mufflers later, these do look bizarre.
    I went with the RJ final drive just because the silver paint fits better with the look.
    I don't think the Turbo final drive is any different ratio.
    I boiled the carbs in my new UT cleaning tank and that turned them black.
    I just picked them up from being vapour blasted so now they're ready for assembly.
    IMG_0796[1].jpg

    2020 01 17.jpg
    IMG_0799[1].jpg
     
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  2. hogfiddles

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

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    some had them, some didnt. If you want to add one, LEN carries very good replacements.

    dfox
     
  3. Polock

    Polock Well-Known Member

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    i think the mufflers look fine. did you use simple green in the u sonic cleaner? it don't like aluminum
     
  4. Simmy

    Simmy Well-Known Member

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    What I hate most about the stock Turbo's appearance is the 80's Battlestar Galactica style.
    These pipes now look like rocket boosters from a 50's sci-fi movie.
    My intention is to get it running in stock configuration so if they bother me that will be on the later to do list.

    I used a WD40 brand cleaner with same result as Simple Green.
    The vapour blasting made them look new again but it sure wasn't cheap.

    brake shoes.JPG

    I inspected the brake shoes I have and couldn't see any signs of separation.
    I don't remember which ones were from the Turbo or RJ.
    The dirty ones were OEM Yamaha shoes, are they the ones known to separate?
    I installed the cleaner ones on the left, all they say is TYT Y515 and GENUINE so I have no idea what brand this is.
     
  5. dkavanagh

    dkavanagh Well-Known Member Premium Member

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    "GENUINE", sounds legit.
     
  6. jayrodoh

    jayrodoh YimYam Premium Member

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    I think the TYT Y515 are EBC shoes. Yes the Yamaha ones were known to delaminate with age but I think it's possible for any shoe with age. I just replace them when I get a bike, cheap insurance for peace of my mind in my mind.
     
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  7. Simmy

    Simmy Well-Known Member

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    I got my seat back from the professional upholsterer.
    I got the cover from Chacal and he also supplied a new strap but the upholsterer didn't want to attempt replacing the strap.
    The rivets need to be redone, has anyone done this?
    I have a like-new strap I removed from my other Seca but I can't remember where I stashed it.
    The front-wheel assy is complete and just awaiting a tire.
    The front-wheel currently on the bike is just a spare to hold the bike up.
    I have 4 gas tanks but the one in place now is the one I'm going with.
    There's a dent in the top which needs to be fixed and I need to alter the mount to accept the Turbo's petcock.
    I need to get going on the carburetors next.
    Then wiring, fuel pump, brake lines, just small stuff now.
    I'm hoping to be ready to fire it up this summer to begin tuning.
    The paint will be the very last thing I do.
    Now that it looks like a bike again I'm anxious to ride it.
    I think it will be the only one on the planet. A real sleeper.
    I've read many times from guys saying if only they just turbocharged the 650 Seca instead.
    Well here it is.
    130.jpg

    131.jpg
    127.jpg
    132.jpg
    125.jpg
    129.jpg
     
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  8. lostboy

    lostboy Well-Known Member

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    Looking good! You will be ready for this summer riding season. ;)
     
  9. Simmy

    Simmy Well-Known Member

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    this website has a calculator which will give you an approximation of your given tire size's diameter

    https://www.rbracing-rsr.com/tirediamcalc.html

    according to this my 16" conversion lowers the bike accordingly:

    front
    OEM 100/90-19" diameter = 26.09"
    now 110/90-16" diameter =23.80"
    lowered by 1.145"


    rear
    OEM 120/90-18" diameter = 26.50"
    now 130/90-16 diameter = 25.21"
    lowered by .645"
    + .5" shorter shock
    total 1.145"

    funny that!
     
  10. Simmy

    Simmy Well-Known Member

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    gearing is about 5% shorter

    which means I need to spin the motor 5,255 rpm's to cruise with a stock Seca at 5,000
     
  11. Simmy

    Simmy Well-Known Member

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    I'm not aware if any replacement air filters are still available.
    The foam seal was 1982 disintegrated so I sealed it with some adhesive lined foam I had on hand.
    Probably thicker but it still fits on the bike ok.
    air filter.jpg
     
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  12. Simmy

    Simmy Well-Known Member

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    Good to have friends with skills and tools. A retired guy I used to work with relocated the petcock mount from the Turbo tank on to the RJ tank.
    Here he is cutting the mount out with his plasma cutter. This is all necessary because the Turbo has a larger and specific petcock.
    There is a return line to the tank for excess fuel pressure.
    s IMG_0862.JPG
    IMG_0864.JPG
    plasma cutter does a real good job going around corners,
    IMG_0865.JPG
    here he is cutting the mount out of the Turbo tank, we made it larger so it overlapped in all directions.
    IMG_0866.JPG
    here it is fit up before welding
    IMG_0867[1].jpg
    welded out and tested with diesel fuel. No leaks on the first attempt.
    IMG_0868.JPG
    while I had the hole enlarged it was a perfect opportunity to remove the big dent in the top of this tank.
    We put a curve in some 3/4" bar stock and we were able to punch most of it out.
    A skim coat of body filler should smooth it out now.
     
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  13. Simmy

    Simmy Well-Known Member

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    carburetors are ready for the wet set.
    I couldn't see anywhere what the fuel level setting is for the Turbo so I'm going with 1 mm below the top of the bowls like my 900 manual shows, they're both Mikuni's but if someone knows for sure let me know.
    I've got the stock jet sizes (127.5 mains in 1&4 and 132.5 in 2&3) in there now.
    I'm planning to up the boost. Is there anyone who has jetted richer for this?
    If anyone has recommendations I'm listening. Maybe best to keep the boost below 11 psi for tuning purposes, wait for the silly stuff until later.
    carbs.JPG
     
  14. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    You are on fire and doing an exceptional job Simmy!
     
  15. Simmy

    Simmy Well-Known Member

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    thanks Chacal. I think I read on your pages about increasing the jets size when increasing boost.
    I think I will set everything up within the OEM parameters (stock jetting, stock boost pressure) to make any trouble shooting easier.
    As stated above the XJ650LJ manual doesn't show the fuel level.
    I filled the carbs with gas today and found all 4 at about 3 mm from the top of the bowls.
    I think this will be ok. I can tweak them higher if someone knows for sure.
    Otherwise the carbs are ready to go on the bike.
    fuel level1.JPG

    fuel level.JPG
     
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  16. Simmy

    Simmy Well-Known Member

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    below is the RJ petcock mount. The threads are formed by just pressing out the sheet metal, pretty flimsy.
    The Turbo had actual weld nuts on the back side, perhaps just because the petcock is bigger.
    RJ petcock mount.JPG
     
  17. 50gary

    50gary Active Member

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    As long as your welding in a new petcock, I switch to the 22mm weld-in bung and use a Pingel. There are now much cheaper Pingel knock offs for only about $40,00 new.
    Cheers, 50gary
     
  18. Simmy

    Simmy Well-Known Member

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    nice thought but I'm not sure anyone makes a mongrel like this for blow-through turbocharged carburetor applications.
    turbo petcock.jpg
     
  19. Simmy

    Simmy Well-Known Member

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    carbs were a complete bear to seat in place. I think this battle took me about 3 hours but I won, yah!
    I noticed @Timbox used ratchet straps in one of his pics to persuade them in but I was worried about my new paint.
    Moving on to the wiring harness now. My open-terminal crimping pliers have arrived and Chacal supplied new terminals where needed so I'm all ready for this now.
    I still need to buy a smaller fuel pump with higher capacity.
    carb install.JPG
    carb installed.JPG
     
  20. jayrodoh

    jayrodoh YimYam Premium Member

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    Now you sound like me. Lol.

    looking good man!
     

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