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1982 XJ650RJ Seat Cover Replacement

Discussion in 'XJ DIY How-To Instructions' started by hogfiddles, Apr 1, 2020.

  1. hogfiddles

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

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    Here’s a tutorial on how to replace the seat cover on a 1982 XJ650RJ. The steps are the same regardless of seat.

    The descriptions for the pics are short. If you need more info, feel free to contact me.

    Her we go!!

    The cover was gone, and it was covered with a torn, ratty, rubber sheet. Here’s what was left of the foam. It’s torn, worn, and has mouse holes.
    C60EE072-197E-4B0E-908D-C5DBB016E025.jpeg

    See what I mean? It had also been reshaped a bit.
    C53CC4DA-ACC5-4DB7-A87E-0027DC7C2F0A.jpeg

    Old foam has been removed. I had to clean the hardware, and replace a couple parts.
    FA2F138E-22F5-46BB-9876-B9DDCF77A5C1.jpeg

    Newer seat foam from eBay.
    703869CA-3066-4FAC-811B-D5D3CDDBD491.jpeg

    New seat cover (Outside) from XJ4Ever.
    B57B7B23-232F-4C07-ACBA-2768CFBB05C4.jpeg

    New seat cover (inside). Notice the quality fabric, thickness, cushioning, and stitching.
    11F98794-6386-40D9-B02B-02BE324B06BC.jpeg

    Place the pan/foam assembly on the cover. Mark the center of the cover at the front and rear.
    C18A9FBC-5F61-468D-9597-D538141B4AAC.jpeg

    Staple the front, keeping it centered. When you staple:
    1. Use 5/16” staples
    2. Keep all your weight on the stapler. Otherwise, it will bounce a little and the staples will not seat all the way. I lean almost all my weight on the front of the stapler, leaving just enough to depress the lever.
    3. Keep a towel on your bench, and keep ALL tools off. You DONT want to puncture your new cover.
    CBB6C927-7216-46F1-861C-FA3FB40CE7C0.jpeg

    Staple the rear, keeping it centered.
    134E6561-2C53-4496-A21E-AFB0DBCF60A4.jpeg

    turn it over to check symmetry.
    49ECE5B1-0581-411F-811B-7AD92A64F4EA.jpeg

    Stapling. The only reason my other hand isn’t on the stapler is because I was taking the pic!
    33638A44-021C-47C0-9E1E-45E403E3E0BD.jpeg


    .
     

    Attached Files:

  2. hogfiddles

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

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    Now staple left and right side, measure carefully so that it is even on both sides.
    F005E3DA-AA52-4229-9B24-EC750F71F6D5.jpeg

    Staple from “9 o’clock to 12 o’clock”. The single staple on the upper right is just to keep the cover from pulling left.
    63791B62-D758-46FB-93B4-7E9B086FA8BD.jpeg

    staple from “3 o’clock to 12 o’clock”
    FFE1EB48-3B5F-4884-8298-DA465F13EBEA.jpeg

    Turn it over to check symmetry.
    6A2CC251-562D-44E0-BB9A-5C7857E03C47.jpeg

    Double-check that the sides are even and smooth.
    4C1FDED4-E2A9-4D94-B823-FF3E26C47E65.jpeg

    staple down the sides part way, keeping it even.
    C903D356-9CD7-45E8-868E-3BD7C72A7EAB.jpeg

    Fill in the gaps.
    B61C4E63-9866-4647-86AD-CA8617E33A61.jpeg

    Turn everything over to check symmetry.
    D9B70599-6F65-49C6-A762-DFFBABBD2D16.jpeg


    Finish stapling around the corners. Tuck, fold, pull, etc... to get wrinkles out, and staple. This where you’ll need some hand strength here.
    04032D18-8E77-4B88-AAF6-2C7715C1DC31.jpeg


    Double-check symmetry.
    7E8B81BF-737D-4C36-A29C-B8DAEEED78F6.jpeg

    The two curves on the sides are the most challenging part. But, hand strength and taking your time will get it finished nicely.
    19AE4985-FAD7-4F04-891E-AA387EAA7259.jpeg 78753834-853D-4916-81FB-D646FD5B3D21.jpeg
     
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  3. hogfiddles

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

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    The only tools used, so far—
    -Stapler
    -5/16” staples
    -Hammer to seat any staples that didn’t go in enough
    -Screwdriver to pull any staples that I didn’t like.
    -Tape measure to verify centers
    99BCCFCF-D6B0-415C-84EE-F510B59CB29B.jpeg

    Add the hardware
    3D167FEF-65FC-4057-B4CE-E00451B3D600.jpeg

    Re-attach the seat cowl.
    85D050B6-FEE2-4C94-8E41-F6FE96AD4953.jpeg

    Turn it over... and say, “Ooooohhhhh!!!”
    A0D07045-AFEA-4E84-9172-85B83D1601F1.jpeg


    Re-install the assembly for now. A3FD240F-0617-4DCF-986E-4D08729D3F49.jpeg

    Next, I will be installing the Strap Kit from XJ4EVER.
    F85A126B-0C61-4BBE-B47E-D4A62F744F65.jpeg
     
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  4. hogfiddles

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

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    Ok, Now for the strap.... this is the complete strap kit from XJ4EVER. I did take a couple shortcuts.... but the instructions that come with the kit are very clear.

    the shortcuts I took:
    1. Drillpress/bit to remove the end of the rivet
    2. Brad-point bit to make 1/4” hole
    3. Shop press to expand rivet

    follow along!

    I started with a dry rotted belt that had shrunk too much, and another that was ok, but the hardware was rusty inside and worn. Here’s the right length belt for my pattern, along with the kit from XJ4EVER.
    8CE41F95-A448-405D-8057-A46ED7445A34.jpeg

    Rivers drilled and hardware removed. Now I have my pattern. No need to measure :). Mark the length, Mark the holes.
    375F5219-C70F-4080-8D9E-CCFD3ED66AA0.jpeg

    Lay the old belt on top of the new one to do that.
    ECE2A6BA-F7D6-4557-A01D-30BECEC7730A.jpeg

    Holes are marked. I took an extra step to measure and mark center, too, before I drilled.
    7C0F1065-1364-4DC5-958E-EF800B6AA6B0.jpeg

    I don’t have a 1/4” leather hole punch, so I used a 1/4” brad-point drill bit. Support the belt on a piece of wood. Drill slowly so the belt doesn’t twist. Use a SHARP bit. After drilling, use a precision screw driver to pull out any bits of material or wood that is stuck inside the belt.
    0A36B921-1350-4A52-96E9-5CC7B7864CA8.jpeg

    Holes are done, both ends.
    9C2B24FC-293B-4510-9295-23E68B6E9BA2.jpeg
     
  5. hogfiddles

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

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    put the inner plate through the loop fold flat and crimp it tight
    59F6DD62-4C54-46B2-908B-FD48B74FCB62.jpeg

    insert the rivet through one washer, insert it through the strap. MAKE SURE YOU ARE INSERTING IT FROM THE OUTSIDE. Place another washer (or washers...as per included instructions). Use an expansion tool, as per instructions....I don’t have one, so I used my press.
    54511632-921B-4B8F-B08E-D52525C6795A.jpeg

    All done.
    98048494-F4ED-473A-8A31-4D5DF1204F8C.jpeg

    Both ends.
    023CE4AA-E9B4-4B55-861D-00EF38D8D685.jpeg

    Now comes the scariest part of the whole project—- yup... you gotta poke a hole in your cover. Actually, TWO. Do this wrong and you just ruined your new cover. You have to make two holes for the bolts to go through. Use a sharp awl, and poke gently (rotating the awl helps) FROM THE INSIDE of the bolt hole first.... that way there’s no guessing from the outside!!
    DF4FE9FB-0555-48B3-8E4C-461BF3E26557.jpeg

    Now, gently ream the hole just a bit from the outside.
    186C52EC-BE49-4DBB-A980-9D99FC2388FF.jpeg

    Carefully snug the bolt through the cover and tighten it down just enough for the cotter-pin holes to be accessible.
    1CF26BE2-7D16-48F7-BC10-3DBDAD8529BB.jpeg

    Insert the cotter-pins.
    F2C71375-062C-4A5E-8D60-C71901227AD4.jpeg

    Both sides are done.
    E2434909-2AFD-41E0-92EC-1F61E661AED5.jpeg

    Belt kit installation is completed.
    B5D07811-557F-429E-AC00-6DCA60AC71F7.jpeg

    seat is back on the bike. All done.
    1FA71F5B-A301-43BE-9CB9-BB8FDD18A837.jpeg

    By the way, here is a “before” pic.....I found it on my iPad. :)
    6F64822C-F676-4F6E-9847-D18FC057CE7C.jpeg

    Lol— I just found my “when I first acquired the bike” pics.

    37221328-0C83-4DB2-9A36-FDD8BD24570E.jpeg

    81FFDB5C-9D2C-46C0-8C6B-69FACC6CDF7C.jpeg

    Yup, and “it ran good last summer”.....you should have seen what the carbs were like. If you were to ask me, it hadn’t run in years......

    I digress...if you have questions on seat cover installation, contact me :)

    now I’ll unlock this forum !!
     
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  6. jayrodoh

    jayrodoh YimYam Premium Member

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    Great! Now just send it to me and I'll test it out :)
     
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  7. hogfiddles

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

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    So, in the “what did you do to your yamaha today” forum, I have been freshening up a different 650rj tank.

    My 650 rj is actually going to be finished as a Canadian Red bike. The silver scheme will be stored so I can dress it as either color, just for fun.

    Here is a pic of it with the cleaned silver tank. Eventually, the other tank that I have got it will be repainted ( it’s mostly stripped at this point).

    ED017847-2A95-4C3D-AAF4-E62AEF52BCA2.jpeg

    It’s a far cry from what it was when I got it.....scroll back up through the forum to see the “before” pics.

    I have everything except the fender for the red, and the fender is on the way from Len CHACAL... of COURSE he would have it!! If I don’t have it, or Toomanybikes doesn’t have it, LEN will !!!! THANK YOU, LEN!!
     
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  8. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    De nada………...
     
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  9. Huntchuks

    Huntchuks Well-Known Member

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    How do you get to your lathe?
     
  10. hogfiddles

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

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    Right now?? I DON’T......lol
     
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  11. tj.

    tj. Active Member

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    Great job on the seat! Thanks for posting.
     
  12. Nuch

    Nuch Well-Known Member

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    You need directions… or should I say something that reads more like a treasure map…
    I cannot confirm or deny that what you seek is worth the journey. I would be remiss if l did not advise you that this task should only be attempted during daylight.

    - Once through the shop door, there is a lightly traveled path. Go 3 paces past the pot belly stove.

    -Take a hard right, do not go left. Keep walking… Look up and locate the shop lamp, it’s power cord should guide your way.

    -Two more paces, then proceed past the coffee that’s just been brewed… Help yourself; There's powdered creamer if you need it.

    -You’ll see a bevy of fine grain wood stock. Please don’t “fiddle” with the musical instruments that are either in the process of construction or in line for repair.

    -Disregard the collection of 700 sissy bars. They are not for sale… Or are they?

    -Climb over the library of sheet music.

    -You’re almost there. Is that apple cider you smell?

    -Continue.

    -You will pass bins and boxes of XJ OE, NOS and a veritable smorgasbord of Unobtanium. Let not your knees weaken.

    -If you find what you seek, burn these directions.

    Remember you should not take this journey lightly…
     
  13. hogfiddles

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

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    “Happens to every guy sometimes this does” — Yoda
     
  14. hogfiddles

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

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    As shown in another forum, here’s what it looks like now with the Canadian red paint on it..... and the seat cover kit from Len really looks good now!!
    11DE63DD-BC14-4E48-9BCB-3C254EAE4349.jpeg
     
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  15. Fuller56

    Fuller56 Well-Known Member

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    Geez Dave,
    That RJ looks good. I was going to pick on you about all the stuff behind it, and the engine case cover that needs polishing but decided against it. Instead I will just ask you how you are going to get it all the way out to where you can ride it?
    Lazarene the Midnight Maxim is now, finally fully registered and legal! Even after finding an error on the Va title in the VIN.
    John
     
  16. hogfiddles

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

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    THATS simple......I just hafta move everything that’s in the way out of the way——
     
  17. Fuller56

    Fuller56 Well-Known Member

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    So, if you started yesterday, moving what is in the way, out of the way, you should be able to ride that RJ by Thanksgiving? :)
     
  18. hogfiddles

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

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    Of next year
     
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