81 xj550 project

Now I feel old when you call them "super old"! Amazing how great music helps break monotony.

 

Looking slick!

 

Thanks. Amazing what paint, degreaser, polish and a lot of time can do.

 

It was a joke...... I know who The Who was. Not was, is...... Well, maybe was.

Was(not Was) was a different group ....

Dave

 

Hey Saftie, here's your set of carbs ready to send back to you!

After:



Before

 

That is truly a masterpiece Dave. Thanks so much. Even though most of the bike will be blacked out, I decided to keep the carbs as they are. They will be the center of attention.
But I am not looking forward to squeezing them back into their place... worse than getting shims out

 

A little warm air from a hair dryer or heat gun, and a light smear of oil... You'll pop the carbs in in a matter of minutes.

 

Yes, I read about it. It will be fine, I am sure. still not looking forward to it. There is also a certain fear of breaking or mis-adjusting something - for no reason I assume.

 

Meh... One person has trouble putting them in and everybody panics.

 

I believe their claim to fame was that they were the loudest band in the world, so three blocks is close!

 

Wow, that's a great job. Mind PMing me what you charged and what you did to them? They look fantastic.

 

New forks came in, shims and new chain on their way. Thanks Len for another super fast order processing.
Need to think about upholstery very soon. Not attempting myself. The upholstery shop in my neighborhood doesn't do it because they don't glue, only staples. If anyone here has those skills, please let me know. Else I need to look around and hopefully find something this week before I head out for Europe.

 

new shims are in, new measurements are all within specs. one more thing to be crossed off the list

 

Hello I too am doing some work. Could you tell me what Year and Model Suzuki the Gas Tank came from?

Thank you Richard

 

Hey Richard,

It is a Suzuki GS550 tank, year is around 80, I think. I just did an eBay search for "suzuki gs550 E tank" and it comes up.
I looked at a lot of tanks and picked one that had the shape I was looking for.
Making it fit is a different story though. The tank is narrower on the inside and
I am also having it welded on top to close off most of the neck gap (or whatever you call it). My tank is at the paint shop so I can't take pics for you. I should have it back in 2 weeks.
but here an old pic of what i mean:

 

Thank you so much for the reply..... I start looking today. Best luck on your build.

Richard

 

Cool, it's a good looking tank I think. good luck to you as well. Ps: you would also have to come up with your own mount in the seat area.

 

Swapped forks today. Dave spotted it right in my intro thread, the originals were bent. Hardly noticeable but still off. Now everything is nice and straight.
I also managed to finally put the new taper bearings in. Big thanks to Len. His parts were the correct ones and different from the previous parts I found on ebay that were supposedly for my bike. Lesson learned.
Next would be to put the engine back in but I think I will ask a friend to help me with it when back from business trip in 2 weeks, or maybe tomorrow during the day if I find the time. tonight, I will look into handlebar controls. I hope the original brake fluid reservoir still works considering the angle of my clip-ons. Most likely not. I did buy an after market set (left and right controls) but I don't think the piston diameter is right and I actually like the low profile design of the original.
any advice on angle is highly appreciated.

 

If it were mine I'd have a dummy oil tank filler welded into that gap. Give people something to think about.

 

Huh, nice idea. Too late now but maybe next time.
Also thought about speedo or some other gauge but there was just not enough room.

 

Oh boy..
Will take some convincing to get it out.

 

Try putting a grease gun on the brake bleeder. You can get a LOT of hydraulic pressure that way, and when it does pop, it won't become a projectile the way it would with compressed air.

 

Great. For now it is soaking in DW40.

 

Think I made it worse by "tapping" it a little too much. Now it sits in there even deeper. I found a 'like new' assembly on ebay, so the one I have now goes on the for sale pile.

 

I'm telling ya.... Try a grease gun. If you pushed it in, the grease should easily push it out. If you can push it out , clean it, and the price goes way up

 

I don't think that water displacement is the problem here. Use a penetraing oil, like PB Blaster or Kroil.
And use the grease gun trick. If you can tap the piston in it will pop back out.

 

x2 on that. You need a penetrating oil that will get IN there.

 

Back from business trip and managed to spend some time last night.
engine is back in, yay. Tank and headlight is still not done and will take a little longer. Bummer. I guess wiring is next..

 

Throttle cable will be replaced. I know some of you will notice the kink in there.
two questions, have not yet looked them up in manual: where the coils are attached, do they need to touch bare metal for ground?
the right hand side coil is missing the cylinder numbers. Which plug goes where?

 

1. No

2. Doesn't matter, the both plug wires fires at the same time; twice per engine revolution. Just make sure the coil with the orange wire feeds #1/#4 and the coil with the grey wire feeds #2/#3.

 

Great. One coil has labeled plugs, 1 and 4. The other one doesn't. So it doesn't matter which goes where for that one, 2vs3? Just clarifying.

 

Correct.

 

Shiny...
also installed battery box and that top tray. Wiring is next, I bought a second wire loom, just in case.

 

oooooooooo, looks great!

 

Oooooh Daddy! Them's some pretty brackets! Clamps too! Where'd they come from?

 

Keep showing brackets liek that and I'll have to invest in a milling attachemnt for my lathe.

 

Found them on ebay a while ago, from Australia if I remember correctly. Not cheap but I sold a pair of 650 side covers that covered the costs.
and yes, they are even prettier in person.

 

Happened to come across the old inner fender. Didn't plan on using it but it makes a lot of sense. Some minor cutting and it works perfectly..
I also realized my new fuse box is too high to mount it where the original one was. Not going to put it where it is sitting right now. More reading about aftermarket fuse box upgrades on the to-do list.

 

Is there a drawing somewhere that lists what/where each relay is? I think I have seen something like this, basically a map of the wiring and where each one is located on the bike, but it could have been for my MV, not sure. I am looking at the wiring harness and there are three relays I don't know what they are. And going through a black and white manual is a pain. All are up where the coils are. One is the flasher. What are the others?

 

Never mind, found it in my online manual on the last pages just now

 

Very cool writeup:
http://xjbikes.com/forums/threads/the-ultimate-relay-switch-sensor-and-diodes-guide.27543/

 

Where did you get your upper fork clamp?

 

Fz 600. I cut off the mount for the ignition switch which sits up front. I think there is an older pic that still shows it. I removed it so I can see my speedo which will sit in the headlamp bucket.

 

I love this thread. Just got a 1981 Seca last night and plan something in the near future for my girl friend...

 

Saftie, re: your fuse box, I mounted mine in the same spot the OEM fuse box was, but right to the air box. Looks great and fits perfect.
Had to cut the plastic a bit that was there but it worked.
-EM

 

Thanks.
Yes, I will install it where the original box was located.
Only issue is height but might get away with trimming it a bit.

 

Ok, got started on wiring. Idientifying everything is an issue. Started thread here: http://www.xjbikes.com/forums/threads/minimal-wiring.66321/

 

you better get a beefy battery... that cigarette looks like it'll pull some hefty amperage...

 

i love it when a plan comes together!