What did you do to your Yamaha today?

Trip Odometer Reset Repair XJ650 Turbo

#0: The Trip odometer shaft breaks because Yamaha put a snap ring slot in the middle of the shaft.
#1: Find a replacement shaft. I found a 3mm diameter screw driver
#2: Cut the Screwdriver to 100mm in length and grind the edges flat.
#3: Cut slots for the snap ring using a Dremel cutoff wheel.
#4: Check that the end pieces fit and the snap ring snaps.
#5: Insert the new shaft into the speedo.
#6: 3D print a press fit collar to hold the shaft in place.
#7: Put the Reset Arm on the end of the shaft with the snap ring.

 

Last one for the day.

Started polishing windscreens. Pretty good progress since I haven't bought a headlight polishing kit yet. The one on the left was black when I started. And I mean black. Painted black.

 

Fully completed winter project #2. New LED bulbs from @chacal, mediocre face resto, speedo mechanism cleaned and lubed. Speedo clutch cleaned up and ready to be greased. Will get new speedo cable in the spring and hopefully will cure the jumping bean.

 

85 700 air
earlier I had a vacuum leak at running temperature, I serviced carbs 12,00 mi.ago when I got bike [ T.S seals, pilot O rings, F.R. O rings].
The carbs looked clean, didn't need attention. ran perfect till now.
taking the advice from members, replaced intake manifold gaskets. while the rack was off, I replaced the float valves and seats.
I had a hellava job wet setting. the after market F.valves are 1mm longer. I dry set at 17mm. took a long time to get wet correct. normally a easy gig. after reinstalling, cyl# 4 not "workng " pipe not getting hot. - ohm'ed the coils, pri/sec within spec. new quality spark plug wires, new plugs. I visually checked, spark ok. plug comes out wet. swapped the plugs around, switched #1 & 4 s.p wires. all fittings tight air and fuel.
I found a use for my gunson color tune. at idle no color. under throttle yellow flares. also can see the C.T. plug firing.
so I pop the rack and clean the pilot circut with can carb cleaner,canned air, and a piece of clutch cable.
took out a/f screw I got squirt going though, reinstalled, same thing,
no change. turned the a/f screw out whilst bike was running, no change. I have spark, plug is wet. compression test, I don't have the tool, might have to get one just to check it off. don't think it's the issue, . It hummed perfect aside from idle creep. bike starts easy quick, and idles on 3 clys on a bench sync. -- I would think I have to reclean. plug is wet, got cleaner stream though circut, most likely not enough. if only there where info on the importance of thorough cleanning, like a church of something .

 

I've been playing with this for a few days.. and it might take a bit more
The spring clips on the glass fuses are breaking and I'm trying to replace the fuses with more modern blade type.
Went through a couple designs before settling on the last one. Its a bit tricky getting all the wires to line up in the bike.
There will be a snap on cover, and I'm going to put holes on the bottom so you can visually check the bottom fuses.

 

Running some tests to see if its possible to print these connector shells.

 

Made new connector shells.

 

Excellent job!

 

Pretty neat.....what material did you use?

 

I used PETG which is becoming the default plastic to print in. It prints well, has a good temperature stability and doesn't smell. I printed a part for the dashboard in my van in PLA, but it warped in the hot sun. I haven't tried ABS or Nylon. This should probably be nylon, but we will see how it lasts.

The weak spot is the long lock tab. Its going to be prone to breakage since the layers are printed perpendicular to its length. I was trying to make it mate exactly the same so I could only change one side. I am considering using a different lock system for when I change both sides.

 

Today's project. Throttles. It takes an hour or two to create a simple model like this. Usually 3-4 test prints to find errors and correct them. About 50 U.S. cents to print the final throttle.

 

Carbs flooded my 550 crankcase and sprung a few leaks on the oil pan and clutch cover.
I knew I was set too rich, but I didn’t know my fuel tap would leak so bad..

anyways gaskets came, fixed that.
Installed the 4-1 system I found, that muffler was horrible though so I switched it out with a much shorter one. Will be welded on if I like the sound .
Also, the 4-1 I have allows for full access to the oil filter and housing. It also allows for a center stand, although I keep mine on the side and mount it on when I need to use it.

yanked the carbs and replaced the 1 fossilized airbox boot, all other 3 are still soft?

tore down the carbs, replaced the diaphragms without having to break/cut anything
Replaced the float valves and reset them.
Replaced mixture screws and bowl gaskets

just need to wet set them today & mount them back up some other time .

then the 550 just needs some fabricated oil cooler mounts, rebuilt petcock mounted, new fuel line & filter, fresh oil, and tighten the drive chain a bit.(and a detail) I’m really excited to hear the exhaust, and see if the oil cooler won’t leak/work. I also think it will run better then I’ve ever had it!

Colorado just got it’s first snow yesterday, and it’s definitely here to stay until about April/may

 

Replaced the fuel rail orings, and T as well

finally no leaking, I’ve been going mad thinking it’s been the bowl gaskets..

although boy do I hate this process

hopefully the third times a charm…

on the bright side, I got blessed with a crisp 19 degrees to get out and get some work in

 

Pulled the wheels and got some new Dunlops mounted. New wheel bearings, fork seals done, and updated the front brake rotor to an EBC vintage-look disc and replaced the rear brake pads. Just in time for more snow. Rolls a lot nicer and the front end doesn't bounce quite as much as it did when I bought it. I thought that was just how old bikes felt. Apparently the forks were almost dry.

 

Removed and rewelded on of teh tail fairing mount tabs - which was 1/2 inch out of place!? One closer examination I noticed a bunch of weld by a PO in the vicinity - unusual spot for damage.. at the same time I realized the extra seat catch was on the wrong way around too - I've only had the bike about 6 years

Darn - I checked my profile... Make that 8 years!

 

Super cool eBay find
Will mount this up along with my next upgrade to the XJ550

i wonder, will this make a noticeable in handling or ride quality?

Also got the bike titled, registered, and plated, finally. (Purchased without bill of sale, or title)

custom plates are in the mail

more updates coming soon!

 

Noticeable difference*
I thought I fixed that!

 

Replaced the old D404s with Metzler Roadtec 01. Also put the rebuilt Koni shocks back on.

 

chem dipped carbs this week, 24hrs ea.


wet setting was a easier gig this time.


extra: I took a break at 4:20 before I reassembled the rack, -whats wrong in this picture ?

 

Scored some side covers for the 550

repaint them black, or silver?