G'day from Oz. 'Project X' XJ600 custom build

Hello all,
It's been a while since I tooled on bikes. I haven't ridden in over 2yrs though due to work though I'm still very much interested in building them.

Apart from owning a KTM 640 SM I haven't had too much to do with road based bikes. I've launched into a custom build on a 1984 XJ600. It's going to be a stripped down build in a Tracker / Brat style. Throw on a set of chunky duel sport hoops, Moto bars, modern electrics and LED lighting. See where it evolves too I guess...

There's not much pre diversion stuff online so I thought I'd share my build. Hopefully learn some stuff and not get too flamed along the way...

Unlike my previous 08 KTM 300 build this build has no set plan. Just more of a feel as I go and letting the bike evolve. I'm planing on reusing parts lying around and bits I can beg borrow or steal off mates etc. A juxtapose of styles so to speak.

The donor...

44,000km stockish steed. With 3mths rego $500





The XJ was the first of the inline 600cc 4 cylinders out of Japan. Not blistering performance though in 1984 was pretty respectable. Twin disk front end, single rear, mono shock and linkage swing arm.

It was belted with the ugly stick of 80's style though. Chunky and a little over the top.

The plan, strip and sell what's not needed. Enhance what's left to make the lighter bike handle better and give it a style of its own.

Into the shed for initial teardown.




First to go was all the excess body work. The 20lt tank is a little excessive for what I'm looking to build. It doesnt really have the lines I'm after either.

To be continued...

With bodywork, tank, seat and cluster removed I finally got to see what lines I am working with. A blast with the pressure washer removed most of the built up grime and oil residue.




The carbs were removed for cleaning. I'll put them through the ultrasonic bath and treat them to a rebuild. The previous owner had fitted cheap mesh style pod filters. These went straight into the bin. I've sourced a factory air box to go back in place.



The factory clipons were swapped out for a set of factory Renthals and mounts I scored from a YZ250. The loom was disassembled tagged and removed. I plan to use a modified / simplified version once re assembled.




The front end is in great condition. I'll freshen up the forks with seals and oil. A set of fork boots also

Brakes will also get some love with a new seal kit and possibly braided lines.

I'm taking influence from the 'Brat' style of bike. This comes from Brat Style tuning house in Japan. This is where the style cues will stem.

"The most defining characteristic of the "Brat" though most definitely has to be the low-profile two-up seat that affords the machine a long and low look quite indescribable or matched by any other machine genre." - Dime City



I turned my attention to getting the XJ in proportion. I managed to source a tank for $60. It's from a 81 GPZ550 (I think) and really suits the XJ. Then it was the rear subframe. This was de tabbed and shortened about 200mm. A local Moto exhaust guy is bending up a rear loop to close up the subframe.






The tank had a few paint coats applied over the years. A quick cost of paint stripper and a wire brush and it came up a treat. There's a little rust inside. I'll try the molasses / water method and report back on the results.




To be continued...

I want to try and keep the bars clean with minimal switchgear. The standard switch blocks are very chunky and actually double up on some functions between the LHS and RHS.

The LHS side block controls lights, indicators and horn as well as a high beam pass button and choke leaver. It's got a crack through it and is pretty flogged out.

I grabbed a metal Kawasaki unit to replace it with. It's a lot smaller and more robust yet still has the 'retro' look.



The choke leaver will need to be relocated. I've seen 4T 'hot start' thumb actuated leavers that I may be able to utilise else I may just jig up a discrete bracket near the head stem.

Nice! The USA got this as the FJ-600. What did you need to do in order to fit the GPz550 tank?

Mate I had to press inward the underside of the tank 2" back from the rear about 1/2". This cleared the frame.
The front mounts needed to be relocated 1" up and 1.5" back as well as widened slightly.

I will delve though the pics and post up the info.

That's a nice project going on. I also got myself xj600 90' - sadly it's the 60hp version. I am planning to take the cafe racer path with my build. I've already got a xj 550 tank, still checking other options though. Have you chosen the headlight yet?

G'day mate, yeah I'm planning on using a 6x4 rectangle headlight with the addition of a low profile 6" LED light bar on top. I've run this setup on a 24Hr enduro bike and they work really well.



It also breaks away from the 7" round light that you see on every other build.



Here's one setup on an RD400. I think it will suit the lines of the XJ a lot better than the round offering.






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Ok I got hold of a manual today so I'm not so blind moving forward with this project.

I went into the shed today. It's slow going with a 10 day old baby to manage. Alas I got the rear hoop from the exhaust guy today. $20 well spent !!!



I asked the bloke to give a little extra length so I've got some excess to play around with. I'm thinking of using about 20deg kick up. I have a rear guard from an SR500 that I'd like to cut down and use. This is just an idea at this stage.



I cleaned up some of the alloy bits today getting ready for painting. Removing machining marks etc.



With the fork rebuild kit on order and confirming the process through my newly acquired manual I realised I needed something to undo the forks. 14mm bolt with two locked together nuts solved the problem.



Does anyone know if there is a taper roller bearing kit available for the headset ???

Im sure All-Balls has a kit. If you can't find it try looking for fj-600 kit. As zap said earlier its the US version of this model.

Thanks mate I'll look into it.

Ok so I got the motor out this morning. Man it's a heavy SOB. Almost popped a grape out my date trying to lift it out by myself.





I drained all the oil before removing the donk. It looked ok though smelled a little burnt. Hopefully it's not a sign of imminent death :shock:

Alas the frame cleanup continues. Removing some dodgy welding splatter and rough slag etc. Probably going a little overboard yet it raining out so may as well be constructive indoors !!!

A few more hours this arvo got the sub frame one step closer. I cut the frame out of the up rite stays so I had some reinforcing to weld to...



The hoop sits in pretty good straight up. Will cut the length and work on the kickup over the next few days. This leaves me with a seat length of over 500mm so I'm happy with that.






So far so good !!!

Looking good.

I'd spend some time with a hammer and some clamps on that right side, that gap is a bit large to weld imho

Looking good! Really like the look of the new tank.

SONIC. said:

Looking good.

I'd spend some time with a hammer and some clamps on that right side, that gap is a bit large to weld imho

Click to expand...

I still have adjust the length. From what I've seen it's best to finish the sub frame inline with the rear axle for the best visual proportion.

Got the rear hoop fitted today. Started cleaning up all the welds and getting the finish nice and smooth.

Next up is the strip down of the wheels swing arm and front forks. These will go straight to the powder coaters this week.

Ok so I haven't made too much progress the last few weeks. Juggling a 6wk old baby other commitments are seriously cutting into my spare time... lol

Alas got the tank fitted up properly today.



The old mounts were cut off and the frame cleaned up. The new mounting location was going to be underneath this gusset.

An hour on the lathe had a new spacer machined up.





After a few head scratches it was glued into place.



I fitted a plate on the rear also. This has a captive nut and rubber block to hold the tank down. I also made a little bracket that was bronze soldered on.



The plate will also hold the front of seat down. Next up to fit the rear mud guard donated from an SR 500.




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My Amazon order came through today. Saved a heap of coin than buying here in Australia. Sad really though that's the joys of the modern world.

Fork gators from Rancho. Pretty cool and about $4each





Also grabbed a fork rebuild kit.



As I'm ditching the pod filters a K&N washable air filter for the air box and a big heap of oil filters to keep me going for a while.

Sourced some new hoops locally though from a mate who distributed parts here.

Heidenau K60 in a 120/80 x 18.





There a chunky tread duel purpose tyre. Going to run the same size front and rear.

I know the purists will have a roll of the eyes though this bikes being built for hacking around the urban and dirt roads all under 100kmp/h as opposed to winding asphalt roads at speed.

Nice bike, I just got an XJ600 a little while ago and am not sure what direction to take it in, so I will be watching this thread and maybe get some ideas.

pablohoney said:

Nice bike, I just got an XJ600 a little while ago and am not sure what direction to take it in, so I will be watching this thread and maybe get some ideas.

Click to expand...

Nice one.

Thom York fan maybe

Yes there are a lot of influences out there. I guess this build will be a juxtapose between my love of riding off road yet on a road based steed.

Retro, hipster are all the cliche terms one could use though like all builds it's a form of expressionism at the end of the day.