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1983 XJ750 Maxim Build (Updates and Questions)

Discussion in 'XJ Technical Chat' started by XJ750DB, Dec 16, 2017.

  1. Paul Howells

    Paul Howells Active Member

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    Masochist.
     
  2. XJ750DB

    XJ750DB Member

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    The issues continue on the new forks I received. I was able to remove the to cop with ease on this pair.

    But the socket head cap screw on the bottom completely rounded off... At least this should be easier to drill out and the kit from XJbikes comes with a replacement screw. :/ 20180106_170945.jpg
     
  3. XJ750DB

    XJ750DB Member

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    After letting the bolt sit with some kroil I decided to take another crack at it with an extractor. I drilled out the head and got the extractor in place. It was not budging so I gave it some heat with a torch and it broke loose. I had to used the trick with the upside down spark plug socket and the extensions to get it completely off. The threads were packed with a hard black substance. After I get the forks back together I will be taking on the carbs.

    20180108_185344.jpg 20180108_185757.jpg
     
  4. Simmy

    Simmy Well-Known Member

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    Good job
     
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  5. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    That hard black substance is thread locking compound. Be sure to degrease the threads, and reapply a medium-strength thread locking compound before reassembly. Having the damper rod disconnect from the fork lower while riding may result in the sort of adventure that nobody wants.

    Also get a new bolt. Chacal should have them in stock.
     
  6. XJ750DB

    XJ750DB Member

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    I definitely do not want that happening. Should I put any anti-seaze on the top cap?

    I bought the full rebuild kit from chacal so o already have replacement screws.
     
  7. hogfiddles

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

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    Yaaay!!!
     
  8. XJ750DB

    XJ750DB Member

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    I figured you guys could use a good laugh on my behalf. After I finished rebuilding both forks and I immediately realized something was off. I had rebuilt the wrong replacement fork and now had 2 right forks on my bike. 20180120_151424.jpg
    I rebuilt the correct one and had the same issues with the bolt being stuck in the bottom and rounding off the hex head. I drilled the head off and swapped over the parts for the other fork. After that I put air in the forks, put new handle bars on, headlight, and horns.

    I'm working on replacing the wheel bearings right now so I can take the bike off the jack stands. I also just got braided lines in for the brakes so I will be replacing those soon. Following the brakes I plan on doing the carbs and getting it running again.

    20180120_160938.jpg 20180120_161006.jpg 20180121_160307.jpg 20180121_160313.jpg
     

    Attached Files:

    Last edited: Jan 21, 2018
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  9. hogfiddles

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

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    2 wrights made an airplane-----
     
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  10. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    You could have just run two fenders..
     
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  11. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Yes, but just a little.
     
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  12. XJ750DB

    XJ750DB Member

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    I just got around to putting the front wheel and brake calipers back on after replacing the seals on the front forks. When reinstalling the calipers the right fork was too close to the rotor the fit the caliper on. I had to loosen the nut on the wheel to get the caliper to fit on. The spacer is on this side of the wheel. Is there something I am missing or can this be a little tight after changing the brake pads?

    Also I have taken my carbs to church and reassembled the rack. I still need to bench sync and adjust the float levels. I am going to wait until I get a sight tube to take care of the carbs. Next I plan on checking valve clearances. I got a new valve cover gasket since there is a terrible mess all over my engine from the valve cover leaking all over. Is there anything else I should look for while I have the valve cover off?
     
  13. XJ750DB

    XJ750DB Member

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    20180204_125646.jpg 20180204_125654.jpg
     
  14. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    maybe get some donuts for the bolts if yours are hard

    could be the fork tubes have moved the triple tree out of alinement
     
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  16. XJ550H

    XJ550H Well-Known Member Premium Member

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    main jet washer looks cupped may cause you problems letting unwanted fuel to pass
     
  17. XJ750DB

    XJ750DB Member

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    Could you elaborate on this? I am not sure what any of this means.
    Whats is the best way to check the alignment of the triple tree?
    The main jet washer was definitely cupped on all 4 carbs. I figured they were supposed to be that way. Can I pick up replacements at the hardware store?
     
  18. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Just gently beat them flat with a hammer. Or we have new replacements available.


    http://xjbikes.com/forums/threads/valve-cover-donut-tool-now-with-how-to-pics.40308/
     
  19. XJ750DB

    XJ750DB Member

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  20. XJ750DB

    XJ750DB Member

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    I got the bike put back together this weekend with the valve clearances in spec, a new valve gasket and donuts. I set the carb float levels and got the carbs on the bike. I was planning on doing the colortune and vacuum sync but my tach was not working.

    All of the fuses are working and I have the ATC style fuse block installed. Is there a separate fuse for the tach/flasher? The bulb in the tach is working but the tach itself is not moving at all.

    I have not wired any of my lights on the bike yet and it sounds like I am having a similar issues to this thread but I didn't find the resolution.
    http://www.xjbikes.com/forums/threa...ach-and-others-not-working.66126/#post-463726
     

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