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What I've done to my 550 (long)

Discussion in 'XJ Technical Chat' started by Jon81550Maxim, Mar 14, 2008.

  1. Jon81550Maxim

    Jon81550Maxim Member

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    Location:
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    I can't believe how much stuff I've done.
    Pounded out the swing arm shaft and sanded the surface rust off, greased it up and it went back in nice and snug but not too tight.
    Cleaned wheel bearings and new grease.
    Took motor out and cleaned it and mounts up.
    Adjusted shims--I took out the cams, that way I know it's timed and the cam chain is snug for sure.
    Cleaned up the wiring harness, soldered joints, and cleaned all the crud out of the connectors then gooed with dielectric grease.
    Made new ground wire!!! P.O. / best friend used a chunk of copper house wire inbetween orig connectors and didn't solder the joints (just twisted them), it came apart and caused the rubber on the orig ends to burn and crumble apart to the touch! Lots of sizzling!!
    If I'm not mistaken the ground wire became a resistor.
    Changed the rear signal bulb sockets to 1157's, so I have running lights.
    I used the license plate light wire.
    Took apart the Kickstand, Start Circuit Cutoff and Headlight relays and cleaned them up.
    Quick frame paint job (a good one next year).
    Took apart Left and Right controls, re-soldered contacts and di-greased them up, I can't believe how nice the switches and buttons work now. And alot more power is getting to the lights. Real bright.
    Took apart the Gauge lights, cleaned and greased up the bulb contacts--even replaced the oil level light bulb, it was completly missing.
    Sanded the exhaust pipes and painted them (A Hindle 4 into 1 exhaust!). OH!! she has a real deep growel.
    Put new fork seals in and dust cap on. Someone used RED locktite on the bottom fork bolts!! I had to heat it with the torch to soften the locktite. Thanks to Yamaha's thoughtfull enginering, I was able to use a length of threaded rod with nuts I welded on each end, fit it into the top of the dampener rod, I used a wrench and took them apart--clickity click barba trick.
    New Throttle and clutch cables. New tires. New fr sproket. New rear shocks.
    There's still more I want to do to her, I'm keeping her for life. There's only 33,000 Kms on her. Barley broke in.
    Speedo needle's broke and tripmeter has came off the gear. Needs seat cover. Right side cover...I guess people break them trying to get at the battery and just chuck them.
    Both lower engine side covers. New signal stays.
    Etc..Etc...
    I really appreciate, and want to thank all the people that have spent all the days...weeks, working on Tech threads that help us figure out how to keep
    our joy's alive. This is a truly great website.
     
  2. Ease

    Ease Member

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    Location:
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    How about a before and after pic?
     
  3. Jon81550Maxim

    Jon81550Maxim Member

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    I just took some picks yesterday but have to look-up how to post them.
     

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