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Mod questions on my 83 xj550

Discussion in 'XJ Technical Chat' started by dfknoll, Feb 8, 2010.

  1. dfknoll

    dfknoll Member

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    In about another month, my uncle and I are going to be doing some maintenance on my bike, but i have some questions that i would like to ask the gurus. Firstly, I want to put an inline fuel filter in like a lot of people suggest but im not currently sure of the size of the fuel line or how much i might need. Can anyone give me some insight?

    Next thing is that my stock headlight is really not very practical anymore because it just really is not that bright. In comparison to a friends headlights on his rocket, his low beams throw atleast as much light as my high beams. Has anyone done a headlight swap for this bike? What kind of stuff will i need?

    I have also seen a lot of the members here commenting on how it is imortant to switch out the old fuse box for a new one. Mine seems to work fine, but i would still like to look into replacing it. I searched the site for a faq on changing it out but didnt have any luck. Can anyone point me in the right direction?

    Finally, I know i have asked for solutions with my bike not wanting to start the next day when it gets real cold at night and i have recieved some helpful solutions. Last week i was reading through Ricks carb cleaning faq and i noticed the section on the "Cold Start Enrichment Circuit" and thought there could possibly be an issue here. The carbs were actually cleaned atleast 6 times in 1 week last year by my mechanic just so we could get the bike running again after it sat so long. Could the "Cold Start Enrichment Circuit" be gummed up?

    Thanks for all the help guys and for putting up with my questions.
     
  2. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    On the 550s, the smaller, straight-through inline filter works best. I got mine from chacal although they are commonly available.

    The easiest way to upgrade the headlight is to replace the original sealed beam with a drop-in H4 Halogen kit. I used a CandlePower "SuperBlu" in my '83 and a Hella Eurospec (also from chacal) in my '81. While the CandlePower unit is certainly no disappointment, the Hella really gets the job done as well, both are much better than stock. I doubt the price difference was actually worth it, the SuperBlu was like $20 more.

    The enrichment "wells" are in the side and bottom of the float bowls and as such, are quite susceptible to being among the first things to clog up.
     
  3. Krashen

    Krashen Member

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    The fisrt thing i did was put a inline filter in. The tank on mine is kinda bad. I just went to o'riellys the parts store up town got 2 foot of 1/4 inch fuel line and a 1/4 inch inline filter. Most automotive places say they are for lawn mowers.. well same thing basically.
    The starter thing let me know on that cause my 550 does the same thing if it sits for a day or 2 it takes a while to get it started i've done thurough cleaning on the carbs 6+ times last summer.
    I'm going to switch my fuse and flasher relay out as soon as i get back to my dads shop and switch over to L.E.D.s
    Good luck hope you find your answers
     
  4. lopezfr2

    lopezfr2 Member

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  5. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Sorry, was at work when I responded, now I'm home I have better access.

    Halogen H4 headlights: Hella on the left, CandlePower "SuperBlu" on the right:

    [​IMG]


    Inline fuel filter on my Seca 550:

    [​IMG]

    There isn't really room for one of the big 90* filters.

    When I pulled the rack to swap the carb hats, I cut a little off the bottom of the hose to the fuel junction, so it sits more "downhill" now.
    I have them on both bikes, this was the only pic I had handy.
     
  6. dfknoll

    dfknoll Member

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    I think i will use the "hella" light because my buddy mounted some off road hella headlights on the front of his subi and there crazy. One question about the replacement lights though. Will they draw more power than the stock light? I dont want to have to worry about stuff burning up because of power draw difference. Thanx for the pic Fitz.
     
  7. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    The Hella, while it does draw slightly more than the stocker, is a drop-in replacement. Len has a detailed explanation in his catalog section.

    It pays to ensure all your headlight wiring and connections are clean and in good condition but beyond that it should not present an issue. I've had no problem with either bike as a result.
     
  8. PainterD

    PainterD Active Member

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    I found a 90 degree filter at a local lawn tractor dealer that works perfect on these bikes, where it makes the turn down to the carbs. May want to try that next time your going to change/add an inline filter.
     
  9. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    He has a 550. The ninety-degree filter fits the big bikes fine (I have one for my 650) but as I said, there isn't enough room on the 550s for the bigger filter to fit "comfortably" in there.

    I test fitted both styles to the 550 and settled on the one that fit best.
     
  10. dfknoll

    dfknoll Member

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    Thanks for the in guys. I ordered the parts from Chacal a few days ago and had em sent priority mail cause i wanted them post haste. Got a couple questions before install though. I know bigfitz has a couple of 550's so i hope he takes a look in here again. What is the best way to clean the wiring connections for my headlight circuit so i can take care of any unnecessary resistance?

    I also ordered a fuse blade type fuse box so i will be taking care of that potential problem before it occurs. I also think i am gonna to a quick how-to write up both on the headlight and the fuse box install with pictures. Any suggestions for these? I know there is atleast one write up for fuse boxes already but this would be a 550 model specific write up.
     
  11. lopezfr2

    lopezfr2 Member

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    i used the 650 fusebox write up to do my 550, its exactly the same except instead of the fuses going right to left its front to back. i should snap a pic of mine its probably the only really clean install done on my bike, i even used the fancy label maker from work to label the fuses.

    as for cleaning the terminals get contact cleaner, maybe a small brush, i had to use sandpaper on a few that were really corroded and just take your time.

    i just ordered the hella euro headlight too but chacal said their last one in stock was broken so i have to wait a couple weeks before i can see at night again.
     
  12. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    FITMENT: the stock Yamaha fusebox is very flat...less than an inch tall. These aftermarket fuseblocks are quite a bit taller, and therefore may present some challenges and the need for some creative engineering to place them properly. We offer the following tips:

    XJ550 models (all): the stock fusebox lays on top of the "tool kit caddy", and the forward "arms" of this caddy hold both the TCI (on the right side) and the fusebox (on the left side). These aftermarket fuseboxes will not fit in the same place as the stock fusebox, as the increased height will cause interference with the bottom of the seat pan. The best fit can be obtained by carefully cutting away a portion of the left tool caddy "arm", so that the replacement fusebox can be attached to the top of the air filter housing. Careful positioning of the fusebox will allow you to remove a minimal amount of the tool caddy arm material, thus retaining the structural strength of that arm. The replacement fusebox should them be retaining to the top of the air filter box via two self-tapping screws, or proper sized bolts and nuts. Here is a good image of what it should look like when you're done:

    http://www.xjbikes.com/Forums/viewtopic/t=14200.html
     
  13. dfknoll

    dfknoll Member

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    I ordered the Hella Vision + one. The one thats 20 bucks cheaper. I also ordered a bunch of other parts from len including the 6fuse blade type fusebox for my bike. So you didnt have to do any cutting to fit yours in because i measured the clearance and its pretty close. If you could put a picture up that would be great. It would be cool if no cutting is necessary but i just ran out and bought a dremel 4000 today cause i thought i would need to. Bummer.......................
     
  14. rustysavage

    rustysavage Member

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    dfknoll, that's always a handy tool to have around for all sorts of projects! im sure you'll get your moneys worth out of it
     
  15. dfknoll

    dfknoll Member

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    well. got my parts yesterday and the headlight is in and looks awesome! Started tearing into the fuse box and got a little nervous so i got on here to print a picture of one someone did to there 550. When i opened up the old one my two center fuse holders where missing clips and the fuse was completed by wires that appear to be welded to the remaining clips. Talk about a ticking time bomb! Going back out. Wish me luck guys!
     
  16. chuckles_no

    chuckles_no Member

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    I was going to replace my box, initially, and even came up with a really cool mounting idea for it. Then I ate some muffins. Then had a beer and put a "watch for motorcycles" magnet on my car. Then...
    went to see if my mounting idea would be doable. It definitely would be. But that isn't the point.
    I have a fuse box that looks similar to stock. Actually I think part of it is stock. But it uses the blade type fuses which is not stock.
    I am going to the bike tonight and I'll take some pics and see what was done and post that.
     
  17. dfknoll

    dfknoll Member

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    lol. I am about half way done. I cut out part of the support for the tool caddy with my new dremel. I sanded the edges of the cut to make clean up all that crazy frilly stuff you get when you cut plastic. I made score marks where i am going to put the fuse box. Cut all the wires away from the old fuse box. And i fitted the wiring extensions that i ordered from len and attached all of the output ones.

    Just gotta connect the wires on the input side and screw the fuse box down and test it to make sure everything is hooked up correctly and i am done. I will post pics in here when i have the finished product. Once i got over being nervous and started it was easy.
     

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