1981 XJ650 Alaskan Bobber Project

i don't see any pictures either, just a -

 

I set up a dial indicator in through the #1 cylinder today to verify that the pointer was at TDC. It was off by a tiny bit. I've rotated the engine quite a few times and the marks stay consistent. At this point, I'm convinced the cam chain is stretched and/or the machinist took more off the head than he is saying. I'm going to replace the chain with a new one and go from there. Thanks everyone for the input.

-Todd

 

go for it, i'd like to see how much it changes

 

I wasn't implying that it would line up if you keep rotating, was just mentioning that I rotated the crankshaft back (CCW) to T after installing the chain tensioner while the marker was at the C mark as the manual states.

Did you try going through the process again? The exhaust sprocket looks to me like you're one tooth off. I know it seems like one tooth would move the mark quite a bit, but it does not. For example a 5 degree rotation at the sprocket would result in the tooth physically traveling further than the mark on the camshaft. I can't think of a good way to explain that but I only mention this as I was in the exact same spot you were until I redid the process a second time. It's kind of a PIA to pull off the tensioner and reset it to do it all over again but I got it my third time.

You would have to shave a ton off to be that far off.

 

+1.

Gary H.

 

Update: I finally replaced the timing chain with a new unit and now the marks line up perfectly. I guess the chain was stretched enough to throw the marks off slightly.

-Todd

 

I mocked up the exhaust today in PVC. Thoughts? I like the twin slash cut pipes, but think I need more angle on them to match the rear frame support.

-Todd




upright.

 

i think that looks great!

 

Fabbed up the headlight bracket and got it mounted-

 

awesome work!

 

You'll be into the brake pedal before they hit the down support angle.

Gary H.

 

Nice build.. Looks like the fender mounts were shaved off the front fork tubes, run into any issues? thinking of doing this to my bike.

 

And the sharper the bend, the lesser the powah.

 

They were shaved when I got the bike....I'd prefer to keep them and run a custom brace. I have a smaller front wheel and the forks are raised in the trees, so I may be ok. Won't know if I'm having any flexing issues till I get it out on the road.

 

Not with a mandrel bend

 

Exhaust mocked up today...no interference with the brake pedal


-Todd

 

Looks good, this is exactly what I was thinking about doing for my build, you beat me to it!

 

Yes, even with a mandrel bend. There are limits to everything.

The new mock-up looks good, and should flow well.

You will have fork flex. The stock fender included a fork brace. Should be pretty easy to fab a good looking clamp-on brace though.

 

Well, I was having trouble finding space to mount an electronics box, so I scrapped the original battery box and purchased this one from Billet Proof. Its designed to house an Antigravity 8 cell battery, plus I will have the igniter, starter relay and fuse panel in there. I'll likely have it powder coated black with the fins natural.

 

Dyna Coils mounted up today-