Building an XJ700X from a box

I got my XJ for $200, but besides the rolling frame and engine, everything else is in a box or just missing completely. So, I'm putting a few hours a week into rebuilding it. Between work and my family, I don't want to over do it on the bike. I'm pretty good mechanically and can fabricate alot of things, I need some help/ideas though...

The grips, handles and controls have definitely seen better days. I'd like to replace them with something a little more modern and/or convienent.

My mufflers are basically shot; they're scratched, dented and rusty. I've checked out some references to Harley tapered mufflers here and I think that's what I'm going to go with.

I have an intake box, but it's not useable. The seals to the carbs are torn up and the box itself is cracked. I'd like to upgrade to something that performs a little better, but nothing crazy.

All the lighting is either broken or missing, except for the headlight. I want to upgrade the headlight, I want as much light as possible in front of me. The turn signals and tail light I'd like to convert to LED's. I've briefly read about it here, but haven't got into any actual research.

Other then that, I just have to finish figuring out the wiring harness and get that straightened out. The PO hacked and spliced it up, so I'm having to sort out the factory connections and then figure out where the "custom" work goes and what it does. I don't have a whole lot of time I spend on the internet, so my research comes along slowly.
There's a wealth of knowledge and information here. I can't wait to get some real progress done on my bike and at least get it running.

 

Talk to Chacal. He's probably got a good chunk of what you're looking for, but it's far too long to quote here.

Further information, if you haven't been there already, can be found at THIS site. Also, if you haven't gotten the XJCD set, do so -- it has the service manual in PDF. Plus, if you want hardcopy, Chacal has that as well.

This file, while not quite up to date, will give you a good idea of what he stocks in the way of parts.

 

The CD set will do me alot of good! I didn't know there was something like that out there. Ideally, I need a complete bike to look at so I know where everything goes... but nothing's ever ideal, lol. Thanks for the leads though! I had already found the Maxim-X site and I've seen Chacal's several sales pitches on here, haha.

 

You've no doubt seen the pictures on Hap's site, so you know what they're supposed to look like when they're done; here's mine anyway.

http://www.xjbikes.com/Forums/viewtopic/t=7916/

I've also done a couple of writeups for that bike on cleaning the carbs and flushing the coolant, the last of which I don't think you'll be needing for a while, but it couldn't hurt to have it handy.

 

Sounds like you've got some good times head of you. :

Couple of points to make though...

The best performance upgrade you can make to the airbox/carbs/intake is to return it to bone stock! Find yourself a good airbox on eBay and some carbboots and set em up. Mufflers? That's gonna be a little trickier, but they turn up too from time to time. Expect to pay for them though... If you want to see some improvements in performance and reliability then get yourself some Dyna coils. There's a good install page on HAP's website.

For a brighter headlight, there are HID kits out there that should work well if you can find a place to mount the ballast. Should have a standard 9003/H4 bulb fitment. Or you can go with a 100/90 "offroad" bulb and call it a day.

Oh yeah... And now would be a good time to check and adjust the valve clearances while the bike's tripped down.

And finally, there are plenty on here who'll offer lots of advice and recommendations. Good luck and post up some progress pics! It might inspire me to finally get started on my X-Project in the garage... :wink:

 

or you could get some pods for your carbs, since your carb will most likely need cleaning and stuff you might at well rejet too., becasue the pods need 'em

 

Guys, I gotta chime in here, I would recommend NOT doing that modification.....you could end up with some nasty metled-wire/on-fire issues......

 

Hi, Jakob, you probably don't think so now, but $200 was probably too much. Good luck.

 

This $200 bike is the only way I could afford a motorcycle. I get to customize it some while I re-assemble it. Also, I can make "payments" on the bike per piecing it together as opposed to having to pay $2000 (or whatever) for a complete bike. It also gives me a chance to really familiarize myself with it before I start riding.

 

Jakob, I like your perspective. Taking your time and becoming familar with your machine is a rite of passage to true ownership. Bravo.

 

200 bucks is a good deal as long as the motor/trans is in good condition when you get things together. Just take your time and do things right the first time and I am sure you will have a nice reliable bike again when you are finished.

 

Hi Jakob, I know what you are saying, but my comments come from bitter experience, it doesn't pay to buy an incomplete bike, if you have all the parts you can clean, pollish, paint, it just takes effort, if you havn't got the part there is nothing you can do but pay for a replacement & the costs mount up, say you need brake parts & hydro' lines, it just escalates.
Having said that, I think re-building from scratch as a way of getting to know the bike is admirable & be assured that I and all the members are here to help you, where we can. Wiz.

 

The engine, transmission, wheels/tires and the "major" parts are all there and assembled. I wasn't really clear on that part, but all the small parts were in a box. The instrument cluster was just hanging on, turn signals, fenders and all the small misc parts were in the box. The wiring harness was basically layed into place and only connected at a few points.
The only major mechanical work I think is going to be required is cleaning the carbs and getting it to run right. The wiring harness is second right behind that. Other than that, tracking down all the little pieces that I'm missing is going to be a pain. There was virtually no hardware included either, so anything that is missing (and alot of stuff that was in the box) has no nut or bolts with it either.
I'm just going to buy a big box of assorted metric hardware so I have a whole variety of parts to work with. I usually buy "fixer upper" vehicles and bring them back to life. I'm also a "mod-a-holic" and I can't leave anything alone once I own it. I have to customize everything I own to give it my own personal touch.

 

Same way I purchased my bike, plus my engine/transmission was completely apart! Pictures in my gallery.

 

Nick, did you know the guy who had smallerized your bike?

 

I'd repair the airbox and get some new boots.
You just make more work for yourself installing Pods and trying to find the right jetting.

I wouldn't put a 100-Watt Bulb in the Headlamp; either.
The Alternator can't hand the load. You'll burn-out expensive Alternator Rotors putting more load on the system than it can handle.

 

Not really, I was the replacement for him at my current job. It was suppose to belong to a friend of his who moved across the country and left it behind. Turned out not to be registered to either of them! A bit of paper work, time and I got it registered in my name.

 

Two questions...
1) How can I get the stock airbox back in with the engine, carbs and everything in place? It seems like the only way to get it in there would be to remove the carbs... is that right?

2) There's a few wires I can't figure out. I got a copy of the wiring schematic and got all the loose ends (except for the gauges/headlight/turnsignals) tied up, minus these few. There's a two-wire connector that's supposed to go to a "sender" per the wiring schematic. Where's that at? I have the connector from the main harness, but can't find it's mate.
Also, there's 4 more wires near the cylinder head I can't figure out at all. They're all black and have like a 90 degree spade connector on them (L-shaped), but I can't find any loose connections near there?
It's also been wired for push button start. There's no key and the starter button is busted... so I guess that'll work, it'll have to for now. Hopefully I'm just a few small connections away from installing a battery and test firing this bad boy! I'll be changing out all the fluids first though.

 

there is a low fuel sender in the tank that is the only one I can think of on my X. THe 4 spade connector wires could be for the dual horns. THe the two wire sender end up under the seat? that is where my low fuel sender plug is located.

 

Now that you mention the horns, I think you're right. The schematic says those should be pink and brown though. Perhaps they've been modified, with the condition the harness is in, I wouldn't doubt it.
I don't have the tank on the bike and the tank I do have is completely bare. So that may be the right place for that sensor.

 

Jacob,
I admire your attitude. I don't have enough ambition to take on a project like that anymore.

Good luck dude.

The Buff

 

I've got more time and ambition than money, haha, so this project is great for me. I also like knowing the mechanics of all my vehicles. That's probably why I've never been stranded by my vehicles, or at least didn't know what was wrong with it.