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XJ600/FJ600 51J Project Advice

Discussion in 'XJ Modifications' started by Ciarán, May 12, 2020.

  1. k-moe

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

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    Get as much out as you can with your fingers and some cotton swabs. Follow up with the degreaser or carb cleaner of your choice.
     
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  2. Ciarán

    Ciarán New Member

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    Thanks for the comments.

    I think the brakes are now clean, as much as they're likely to be anyway. I'm not entirely confident they're safe to use, I know some wear on the face outside of the seals is acceptable but there's a weird discolouration deep within the pots. I'll post pics shortly.

    The major discovery of all this, and presumably the reason the brakes were so solidly seized was the complete absence of the outer seal (dust I presume) from both calipers (all 4 pots were lacking the seal). Frankly I'm amazed the brakes weren't in worse condition.

    I'm currently shopping for a master cylinder setup for the bike. New MCs are bloody expensive so I'm considering finding a 22mm mount MC from a fairly modern midsized sportbike. Picking a bike at random to give an example, let's say an MC from a Honda CB500rr, it's probably a lighter bike but with more aggressive braking characteristics.

    Although, thinking it through will I need an MC from a pre-abs bike if I'm going the second hand route?
     
  3. a100man

    a100man Well-Known Member

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    I think my M/C is from a GPZ550 fwiw. Pick something close and you'll not go far wrong. I might even have chosen that one as I could buy a cheap rebuild kit for it..;)
     
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  4. Dave in Ireland

    Dave in Ireland Active Member

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    Assuming the XJ600F uses the same brakes as the 900F, to keep the hydraulic leverage the same I would recommend the m/c from a Honda NT600v Deauville, as it has a nice span-adjustable lever and is just nicer to use. I've been using them on most of my bikes for a few years now.
    Late 90s / early 2000 ones had a mirror perch on them, too.

    Oddly, the XJ900F master cylinder was fitted to my GS long before I bought an XJ, as it was a better feeling m/c than the old Suzuki one - same bore, much better control.
    I'm quite happy with the brakes on the XJ, but if I have to replace the m/c it will be a Deauville one that goes on.
     
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  5. Ciarán

    Ciarán New Member

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    Thanks for all the comments. As promised yesterday here are some pics of the internals of the brakes. I still hadn't pulled the seals or finished cleaning when I took these pics.
    I'm anxious they're not safe to use again. Unfortunately full rebuild kits are also out of stock in the store I use so even if I bought second hand brakes from a breaker I wouldn't be able to progress the brakes much.

    I've been looking around and I've seen a new nissin master cylinder 5/8" advertised in a few places that is on sale for about €120. Seems like a good deal on a brand new set up.

    Hope to order that soon. Then I guess it is time to sort out throttle and clutch cables and brake lines.

    Disassembly of the rear brake and master cylinder is high on the list of jobs too.

    I'm taking my sweet time thinking over every part I want/can afford at the moment but mainly it's about getting this thing mid way road worthy to see what needs fettling.
     

    Attached Files:

  6. Ciarán

    Ciarán New Member

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    Ok so I've just forked over a lot of money for a range of parts. Some are cosmetic which may seem premature but given I was paying shipping charges anyways I took advantage of it to get a few basic items.
    Louis:
    - New throttle and clutch cables (c.€27)
    - New grips (€10)
    - Chain & Sprocket - DID 530VX (€117)
    - New mirrors (old ones were in terrible condition and I hated the look of them) (€49 for two)
    - Chain breaker and riveter (I'm such a beginner at all this - I didn't have one!) (€35)
    CarpiMoto
    - Nissin Master Cylinder (€129 including shipping).

    Tonight I may order HEL braided lines (front €128, rear €43).

    I have successfully removed my old Master Cylinder (had to drill the heads of the screws and then grab the nubs that were left to turn them out). So I had the option of refurbishing the old master cylinder but it's a pretty nasty looking unit now at a cost of €70 for a full refurb kit. I just felt the brand new Nissin was the better choice and required less effort. I'll consider trying to tidy up the MC as best I can to keep it as a spare or potentially to ebay it. The inside of the sight bubble is horribly dirty but I've made some progress in cleaning it. I may invest in a small ultrasonic cleaner at some point but any of the ones I've seen have looked like absolute rubbish or have been ludicrously expensive.

    My main issue now is to determine if the calipers are salvageable (I suspect not) or should be replaced. Opinions welcome based on pics above. If required I can provide more.
     
  7. Kickaha

    Kickaha Active Member Premium Member

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    Is that the same size as the stock one ? changing the size up and down from standard can make a huge difference to the way it feels and not always for the better
     
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  8. Ciarán

    Ciarán New Member

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    Both are 5/8" pistons so I'm hopeful it will be similar. I'll admit I took a chance on it as a beginner at all this. I think there could be quite a lot of work in fully restoring the stock MC I have and there's always a risk in buying second hand parts that they'll also need full refurb. So, the short answer is - I won't know for sure how it performs until I get the bike properly roadworthy and can test it - frankly that's a long way away just yet.

    I'm trying to get it to a point that it is rideable to determine whether I really want to sink the cost in for a new exhaust system, taking on wiring, painting etc.
     
  9. a100man

    a100man Well-Known Member

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    Hi Ciaran, since you are this side of the Atlantic you can try Yambits for brake refurb parts, The calipers look ok to me but once you pull the seals you need to scrape all the corrosion from behind them in the grooves with a plastic or wooden pick. pistons and seals are 25 quids a go and so is the master rebuild kit. If you're going to order a heap of stuff then consider using XJ4ever on here postage won't then be so bad.
     
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  10. Ciarán

    Ciarán New Member

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    Wow thanks for that - I don't think I'd seen yambits before! Those parts look a lot more reasonable than some prices for kits I'd seen on wemoto (I buy from them a fair bit and I find them very good). Delighted that the calipers may be worth saving. Will give them a good clean up and hope for the best.

    Wow the prices for the repair kit for the front MC are insanely different - £53.53 vs £24.99!
     
  11. a100man

    a100man Well-Known Member

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    You can also use a bit of fine scotchbrite to clean teh caliper bores..;)

    PS Did we ever establish where you are in Ireland?
     
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  12. bensalf

    bensalf Active Member

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  13. Ciarán

    Ciarán New Member

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    Thanks a million. High on my list of priorities to get those calipers rebuilt. The nissin master cylinder arrived. Have to say I'm amazed it came from Italy probably within about 36 hours of ordering.

    I'm in Dublin but I'm originally from Mayo.

    @bensalf My bike is registered 1990 but is a 1989 model so I think those may be slightly different. I'll shop round for the lines before I order - but I think the price for them from wemoto is actually a few quid less that direct from Hel (I was looking yesterday but don't have figures to hand).

    I'll keep an eye out for a box large enough to send the crash guard and pannier frames to you - I haven't forgotten.
     
    Last edited: Jul 30, 2020
  14. a100man

    a100man Well-Known Member

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    HI Ciaran

    Sounds like it's coming together nicely. I know the owner of bike shop in Dublin (not well, but well enough) should you ever need close by help.

    Cheers
     

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