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Top end rebuild "running in problems"

Discussion in 'XJ Technical Chat' started by Drake, May 31, 2018.

  1. Drake

    Drake Member

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    Hi guys let me start of by identifying my bike and my problem
    I have a 1981 xj650 maxim non yiccs
    Running Pods and a 4-2 custom exhaust

    I brought the bike with a slipping start clutch so we all know what that means
    Split cases!!
    So while in there i did the top end,which lead to further things like stripping the cases to get blasted.
    With the top end done and rebuilt carbs

    The bike starts very well even in these cold New Zealand winters (choke for 10sec max)
    Bike idles great BUT headers 1 & 2 get hot very quickly while 3 & 4 stay cold for quite some time 3-4min
    3&4 exhaust spits a flame at around 3k rpm

    Work that has been done

    Engine split and reassembled with
    new top end
    New pistons
    New rings
    New valves
    Shimmed vlaves

    Carburettors blasted,stripped,cleaned,rebuilt with new
    Diaphragms
    Shaft seals & O rings
    Jets 45 pilots 120 mains
    Float level set
    Bench synced and then vacuum gauge set

    New dyna tek coils and leads (non resistance type)

    I will upload a running video in the morning

    Your help would be greatly appreciated
     
  2. Drake

    Drake Member

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    Photo 1
     

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  3. Chitwood

    Chitwood Well-Known Member

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    Try a colortune plug. You can order them from Xj4ever
     
  4. k-moe

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

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    What did you set the idle mixture screws to?
    More importantly, are they coarse-thread, or fine-thread.
     
  5. Drake

    Drake Member

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    No particular method just set to 3turns out and fine thread
     
  6. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    Those are huge jets for a 650cc engine!

    Nice looking engine.

    What do the spark plugs look like on #3/4?

    You should perform and compression test on all the cylinders.
     
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  7. Drake

    Drake Member

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    I will do that this afternoon .
    45 is what the bike had in it when it was in its factory form and 120 is what SIGMA racing jet kit gave me as well as a 130..
     
  8. Drake

    Drake Member

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    Unsure why it’s such poor quality but gives you the idea
     
  9. Drake

    Drake Member

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    also one shim added to needle jet
     
  10. k-moe

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

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    Regardless of what it had in it, stock is a 40 pilot, with 110 mains (even in NZ).

    3 turns out on a stock bike is a tad on the rich side, and with your jetting you might be rich at idle (even with the pods). Pull the plugs and give us some good pics of the rings and ground straps.
     
  11. Jetfixer

    Jetfixer Well-Known Member

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    ^^^+1 know is correct the other item did you wet set your floats? Just a thought uneven filling of the float bowls to find out get a container with markings drain one float bowl at a time see how many ounces drain out as long as close your ok . Cheers
     
  12. Drake

    Drake Member

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    Okay these photos wore taken after about 3min of idling
    Headers 1&2 wore very hot by then.burn to touch.
    3&4 wore cold
    Plug 1
     

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  13. Drake

    Drake Member

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    Cylinder 2
     

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  14. Drake

    Drake Member

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    Cylinder 3
     

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  15. Drake

    Drake Member

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    And finally 4
     

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  16. Drake

    Drake Member

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    Will give this a go to thanks mate
     
  17. Jetfixer

    Jetfixer Well-Known Member

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    Okay another question have you taken it for a high speed ride of say 15 to 25 miles and then checked plug , note if you are only checking at idle this is what plugs can do on occasion.
     
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  18. Drake

    Drake Member

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    Bike back fires very loudly on low revs (pilot jet)
    But pulls well when opened up.
    Got upto about 30-40km down my street and killed the engine and checked the plugs and they all pretty much looked like this.. 3rd cylinder was more of a wet black.
    It has only started backfiring from been rich since I took it for its first ride down the street last week.
    It just concerns me how hot 1&2 headers get from idle when 3&4 stay cold.
    Thanks for the reply’s guys
    Guess I need to get some smaller jets say 42-116
     

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  19. k-moe

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

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    1-4 are all very rich. 3 and 4 are both wet. Did you smell gas on them, or is that oil?

    The coldness on 3&4 is the result of the plugs being wet. Those plugs aren't firing well until they get hot, and even then they probably aren't firing well.
     
  20. Drake

    Drake Member

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    3 is still wet even when checking this morning without having the bike running.
    4 is definitely the cleanest plug.
    3 does smell like gass but does look to have oil deposits over it
    Or could that be a build up of fuel from not firing? It does leave a black oily stain when I clean it with a rag.
    Sorry this is my first engine rebuild so it’s all new to me..
    Could I have possibly damaged a oil ring when slidding the cylinder over the pistons?
    What would you suggest my next steps are?
    Thanks again
     
    Last edited: Jun 1, 2018

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