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XJ600 Cafe Racer project

Discussion in 'XJ Modifications' started by GoCrazy, Sep 13, 2016.

  1. GoCrazy

    GoCrazy Member

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    Hello there,

    This is my project that is about to get finished. It's based to 1990 XJ600 that I bought in a good condition. Things I did include:
    - rear frame modifications
    - XJ 550 gas tank
    - aftermarket British style, 7" lamp
    - led turn signals and rear light - bought on ebay, nothing fancy
    - powder coated rims
    - reduced wire loom
    - custom made seat (epoxy resin)
     

    Attached Files:

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  2. a100man

    a100man Well-Known Member

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    Brilliant, at last. I always wanted to see a 550 tank on a 600. In 1984 I had a XJ550 and in 1991 a XJ600 but I always much preferred the look of the 550. Because of that I put a 600 engine into a 550 rolling chassis in the past year or two.
    But I always fancied mono-shock look too.

    Did the tank go on OK? No chance to fit teh side panels I guess. BTW I just had some 598 decals made in the style of the 550 an they look good - better than the avatar - just need to finish spraying my spare panels then fit-up..

    Thanks for sharing, more pics please
     
  3. GoCrazy

    GoCrazy Member

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    I also prefer the 550 look :) Unfortunately, I could not find any bike in good condition. XJ600 seems to be more popular, spare parts wise as well. The tank needs minor changes - XJ 600 has a bit wider frame just below the tank, the difference is minimal, barely 0,5 cm - 1cm. I had to hammer the insides of the tank a bit and I used a insulation tape to wrap up the frame in possible contact points - just in case. You will also have to modify the rubber cushions (sorry if I mix up the terminology, obviously English is not my mother tongue :) ) - they have different length - I used 80 grit sand paper. I don't remember for sure, but I have welded new " U" shaped mounts for the rubber cushions. In my case I wanted to lower the tank to get more aggressive posture of the bike. It's quite probable that you don't need to re-weld the mounts. If you are planning to run clip ons - your handlebars might collide with the tank, depends what clip on angle you prefer. I don't have this issue. In general, it's more or less plug'n'play swap :)
     
  4. desmotom

    desmotom Active Member

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    more pics pls! looks good.
     
  5. GoCrazy

    GoCrazy Member

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    Some pics I took yesterday. The last one shows a side cover from aluminum sheet. It will be bare aluminum for some time, alter on I'll have it powdercoated.

    IMG_20160915_185230.jpg IMG_20160915_185602.jpg IMG_20160915_190936.jpg
     
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  6. desmotom

    desmotom Active Member

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    looks really good! the one thing that stood out to me was the tach/speedo, I would lower it to the top of tank level...but very cool
     
  7. GoCrazy

    GoCrazy Member

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    It will be mounted in a different way once my custom top triple tree clamps are finished :) The one mounted on the bike is just temporary.
     
  8. desmotom

    desmotom Active Member

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    image.jpeg
    You making them? I made them for my project.
     
  9. a100man

    a100man Well-Known Member

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    Nice work guys - thanks for posting
     
  10. GoCrazy

    GoCrazy Member

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    Hey, I managed to start the bike - runs like a charm :) I also took a photo of my custom triple clamps. I need additional milling to do - 1mm around the bolt. For the moment it looks like this:
    IMG_20160922_215038.jpg
     
  11. sybe

    sybe Active Member

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    Looks great!
     
  12. GoCrazy

    GoCrazy Member

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    Thanks :) I borrowed an ellectronic manometer from a friend, hoping to synch my carbs. Also, I found a small oil leak around oil filter.
     
  13. desmotom

    desmotom Active Member

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    Nice job! What did you use to make slots for the pinch bolts?
     
  14. GoCrazy

    GoCrazy Member

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    If you mean those two bolts that tighten the clamp around each forkleg, I haad them drilleed at a local cnc Shop. I think they have used a drill press or something.
     
  15. desmotom

    desmotom Active Member

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    Oh I thought you made them....cost a lot?
     
  16. GoCrazy

    GoCrazy Member

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    The clamp was measured and cut by a friend of mine so it's a little bit different. I know thaat he makes them for others from time to time. I can ask about a price.
     
  17. GoCrazy

    GoCrazy Member

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    Carbs - locked and loaded
    IMG_20160924_162542.jpg
     
  18. GoCrazy

    GoCrazy Member

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    IMG_20160926_190759.jpg The seat has arrived
     
  19. GoCrazy

    GoCrazy Member

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    So, I fired it up and had a ride around the hood. The throttle cable needs shortening and re-routing - at the moment it's under the tank but when I turn right the "wire" inside the cable gets pulled and the bike revs up. Also, one of the exhaust manifolds needs some wiggling as I can hear some exhaust leeks.
     
  20. GoCrazy

    GoCrazy Member

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    So, my happiness didn't last long. It turns out that my bike has cold starting issues. When I try to start it cold, without choke it starts right away and after a 2-3 seconds it revs up a bit and goes down until the engine dies. After that I need to hammer the start switch for 30 min until the battery is dead until it starts again. Luckily, I have a battery that's used as back up for audio installations ( high power stuff). So these are the facts:
    - Originally it the bike was 54 hp but I switched carb boots from 72hp version. I did not change any jets as I concluded that new boots would give more air making the mixture too lean (apparently it's otherwise)
    - the bike runs stock airbox, new filter, original 4-1 exhaust
    - I asked a friend of mine who runs a shop to clean the carbs, I assume he did a good job
    - one of the pilot screws was stuck and got destroyed while removing. I managed to get my hands on a single carb (#4, first from clutch side). I replaced the carb body, using all needles and removable stuff from my original carb. Here's the first mistake I made - I did not check the needle valve/seat. I put it on back together.
    - I managed to start the bike, when the engine was warmed up, I balanced and synched the carbs.
    - after 2 days bike has a hard time starting when cold.

    What I did so far:
    - I found a small air leak from one of the exhause manifolds ( will get it fixed this weekend)
    - sparks (brand new) - black, sooty residue
    - I can feel some unburned gas ( might by the gas that I spilled on the floor accidentally :p )
    I am no expert but all signs on heaven and earth point to rich mixture

    What I plan to do:
    - replace all needle valves and set the float again
    - check floats if they're stuck
    - check for gas smell in the oil

    Is there something that I may have skipped? Should I check something else?
     

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