XJ front end modernisation.

Hello Xj's

I have purchased xj750 1983 for spare parts for my other xj750 1984 Seca, what I needed I took out and decided to make a cafe racer style bike out of the 83 model. Everything is going smooth with the maintenance, I closed the engine, replaced the fluids etc.
The problem:
The front brakes are in a terrible condition, rust, leaking master cylinder. Overall they would require a total rebuild, which is pointless as the bike will get a modern look. Also the system is stupidly complicated.
Solution: Replacing the whole system, buying new calipers, master cylinder and lines.
My question is : has anyone done this before ? I know that the thing to consider is the caliper mounts and spacing so that the break disks can fit. What about the anti-dive system, can i just close it off ?

 

Somebody posted here once about replacing the entire XJ650 front end with an R6 front end: https://xjbikes.com/forums/threads/xj650-to-r6-front-end-conversion-step-by-step.40332/

Maybe it would be possible to do the same thing with a 750 and an R7 front end? Not sure. If you’re looking to replace the whole brake system, it could be worth replacing the forks too.

 

Maybe it would be possible to do the same thing with a 750 and an R7 front end? Not sure. If you’re looking to replace the whole brake system, it could be worth replacing the forks too.[/QUOTE]


Hey, I found the thread and I have found some answers to my question. I am now looking at a new set of forks, probably not ohlins because of the crazy price. I will be updating this thread as I go along the rebuild.

 

So far :
Replaced all the fluids, replaced the existing front brake system ( new lines, new brake lever).
This week finish bleeding the brakes, putting everything back together, muffler replacement, deep clean.

The hard part was removing the old brake system. Rusted, seized bolts and welding shut the brake joint under the light. In order to fit the new lever I had to cut off the old lever housing, the next problem I have encountered was the double bolt that i had to install at one of the sides of the joint. The issue in this case was the fitment so that the longer bolt is not pressing against the forks.

Since, I have the anti-dive system the hardest part is the bleeding, but that's going well with all the guides that I could find here. I bought old used shocks that Ive installed on the bike. Apart from cleaning them, can I do maintenance work ? They feel very stiff at the strongest settings.

The goal is to get it running and pass an road inspection before the 18th as in Warsaw we have the DGR !!!

Will keep updating as more stuff is done.