XJ650 '81 - First solo project.

[Ribo]

As it's forecast rain for the next week here I'm taking the time to make some more mods and do some basic maintenance work....

Got a fair amount done last night:

Took the headlight and instrument bank off and temporary labelled all the wiring.
Removed the turn-signals and housing.
Installed new turn signals at rear - need wires extending..
Replaced the clutch and throttle cables - pretty easy, I was going to shorten them but after taking them off I found they both had some casing damage so I ordered new ones for a 750 SECA and they fit perfectly with a little re-routing...having the whole front exposed with the headlight off and instrument bank off really made it easy after I pull the tank - hey the tank used to be purple, whatayouknow!

The clutch cable on the seca is about 6 inches shorter and the throttle is about 4inches shorter.

Now I just need the new headlight and I can start shortening and re-terminating the wiring. While i wait on that I'm going to change out the brake shoes and wheel bearings and check the damn valve clearances if I get a spare 5 hours...

 

[Ribo]

Little bit more work last night:

Repainted the ignition switch and re-installed
Got the Tach and Speedo installed....this took a bit of figuring out and some research but I think I got it done quite well on the original cluster mounting points on the tree. Trick is that all of these require you to mount them with some kind of vibration protection - i.e. rubber, but this makes it hard to get them stiff enough on the single mount.

Here's what I put together after some trial and error for each device.

1 x Metric M10 1.5mm Hex-bit bolt
1 x 3/8 in rubber-washer
1 x Metric 10mm zinc plated washer
1 x Metric 10mm zinc plated split-washer (compression washer).
1 x Metric M10 1.5mm nylon insert lock nut
+ the original black rubber grommets from the tree holes - WITHOUT the metal inserts.
-----
Here's how looks.... the first photo shows the metal insert cos I had it in my hand but it's not in the bolt assembly..the gauge hole sits between the new rubber washer and the top part of the original rubber grommet...

...
I really like how the front is coming together now...but it kinda makes the crappy stock master C stand out like a sore thumb. I'm all about the electrics now however I need to wait on the new headlight so I can chop the wires down to the right length and re-terminate them. I'll get the master replaced when I have more $$....anyway...I should probably do some maintenance in the meantime....

 

[zap2504]

I really like how the front is coming together now...but it kinda makes the crappy stock master C stand out like a sore thumb. I'm all about the electrics now however I need to wait on the new headlight so I can chop the wires down to the right length and re-terminate them. I'll get the master replaced when I have more $$....anyway...I should probably do some maintenance in the meantime....

Is the master cylinder horizontal on the new bars? I know most MCs made for "cruiserish" bars end up being too tilted on flatter bars. I ended up getting a new MC (and handle) to fit a Suzuki GZ250 for my Kawi KZ440 (when I changed the bars) as it was way cheaper than trying to get a MC from a flat-bar Kawi of the same vintage. If you get a replacement, most all Jap bikes use the 7/8" bar size and MCs for single disk brakes are all the same cylinder diameter and they all have the same brake line banjo fittings.

 

[Ribo]

Thanks man,

Yeah the MC is tilted but it works ok on the drag bars, it's not too far over - it looks a bit awkward cos I had to install it too far upright to make it work. I got my eye on a new MC with a separate fluid-bucket that will firstly give me more room on the bars so the banjo won't be right over the front fork and secondly allow for the bucket to sit horizontal.... but it's out of stock right now. I believe the XJ650 is 14mm piston right?

 

[Sonreir]

I miss my Seca. Also, sorry about the beer. I hate it when I can't find anything made from barley, either.

 

[Ribo]

Haha,

I was gifted the bike but sometimes I wish it was a Seca, then I feel bad cos it was free...

Sadly I'd ran out of my preferred wheat beer leaving me with this Paulaner, which isn't bad. Usually if it's ain't Cloudy and Belgian or German it's not going in my face but I've been known to slum it with the Barley drinkers on occasion.

 

[zap2504]

I believe the XJ650 is 14mm piston right?

IIRC, all the single-disk front brake systems use a 12.7mm MC bore and the dual-disk systems use a 14mm bore. You don't want to interchange them. The stock XJ650 Maxim had a single-disk; the XJ650 Seca had a dual-disk.

 

[Ribo]

Hmm, I pretty sure it's 14mm on the '81 XJ650 with the single disk... don't have my book with me but I'm fairly sure. I'll check tonight.

 

[zap2504]

Hmm, I pretty sure it's 14mm on the '81 XJ650 with the single disk... don't have my book with me but I'm fairly sure. I'll check tonight.

I checked XJ Forever's site and you are correct - 14mm (the dual-disk bikes use a 16mm MC).
From Len's site:
"NOTE: a few clarifications about use of the original XJ650 Maxim master cylinders versus the aftermarket cylinders.

There are a couple of differences you need to be aware of:

a) because the stock OEM master cylinder is designed to be used on the stock curvy "buckhorn" style handlebars, the stock master cylinder reservoir is oriented at a "tilted" (from horizontal) mounting angle. This "tilting" allows the mirror to be properly aligned for the use with the stock buckhorn bars and keeps the reservoir in a relatively level position.

b) the aftermarket master cylinder HCP1808WO [$119.95 complete w/handle & banjo BTW] is designed to mounted on "flat" (or, at least, "flatter") style handlebars, such as the ones found originally on all XJ-series bikes (except the XJ650 Maxim/Midnight Maxim, XJ750 Maxim/Midnight Maxim, or the XJ1100 models.....all of these models used the curvy buckhorn style bars). All other models use fairly flat handlebars, and thus the replacement HCP1808WO master cylinder will work on those bikes correctly; they leave the mirror mounted in the proper orientation.

c) thus the aftermarket HCP1808WO master cylinder is going to leave the stock mirror tilted at a rather crazy and semi-useless angle when installed on any model that had those curvy, "buckhorn" style bars, and we do not have a stock-style mirror substitute that "solves" this problem. About the only solution we offer is to use the "bar-end" style mirrors, which attach the mirrors to a mounting stem that fits inside the end of the handlebars (which requires modification of the grips by cutting away the rubber on the ends of them).

d) Also, on the XJ650 Maxim and Midnight Maxim models, the fluid outlet port (where the brake hose attaches), is facing "inward", towards the centerline of the bike (when the forks are pointed straight forward). The replacement HCP1808WO master cylinders have their fluid outlet port facing straight forward, and therefore your stock brake line has to be contorted to a rather odd angle to make it reach and fit this forward-facing outlet port. We do have available modified rubber or braided stainless steel brake lines for use of the aftermarket master cylinders on these bikes; their end fitting is rotated by the 90-degrees and extended by an appropriate length to allow it to attach to the aftermarket master cylinders properly."

Also check out Airheart's guidance http://www.airheart-brakes.com/pdfs/MasterCylinder_Selection.pdf

 

[Ribo]

Thanks dude,

Yeah, I don't think I'm going to be leaving the stock MC on there - I only put in back on for a couple of days before I started ripping the headlight apart. By the time i get the front end sorted out I should have the new MC anyway which is the separate bucket type.

 

[Ribo]

So just in the process of sorting out all the wiring and waiting on the headlight -- had it specially powder-coated so it's taking a while to come in but I'm excited about it -- after I took a good month to find it...

While I wait I decided to pull back brakes after reading the delamination thread -- these puppies are original so I ditched them taking precautions with the asbestos - eek!

Now the shoes are taking time to get here -- I hate waiting around... but I got stuff to do - the front pads looks fine so I might take the time to check the value clearances....man I hope they are good cos I don't want to spend a day padding them up.

 

[Ribo]

So I ordered the new brake shoes last Monday from http://www.ebay.com/usr/filterkingonline?_trksid=p3984.m1439.l2754

cos the said they would be delivered by Thursday last week.. after getting no tracking number I emailed him a bunch of times with no reply. Come Friday with no brake shoes in sight I opened a case on ebay and within an hour I had a tracking number but they weren't shipped till Friday evening... I suggest not buying anything from this seller unless you want to wait around, miss a weekend of riding and get no communication... Yes I'm bitter cos it's 75 degree's outside and sunny and my bike has no rear shoes...

Before someone calls me out -- yes you maybe aware that i have no headlight right now and wiring that isn't perfect - I'm waiting on that coming in next week but I could have swapped the old one back on easy and my wiring is "functional".

Anyway, I got the brake backplate cleaned and cam/bolt newly greased up... I took the extra time to give it a paint too cos it was pretty scuffed up.. so now I guess I've got to pull the driveshaft cover plate on the other side and do that too.. at some point..

 

[Ribo]

I checked XJ Forever's site and you are correct - 14mm (the dual-disk bikes use a 16mm MC).
From Len's site:
"NOTE: a few clarifications about use of the original XJ650 Maxim master cylinders versus the aftermarket cylinders.

There are a couple of differences you need to be aware of:

a) because the stock OEM master cylinder is designed to be used on the stock curvy "buckhorn" style handlebars, the stock master cylinder reservoir is oriented at a "tilted" (from horizontal) mounting angle. This "tilting" allows the mirror to be properly aligned for the use with the stock buckhorn bars and keeps the reservoir in a relatively level position.

b) the aftermarket master cylinder HCP1808WO [$119.95 complete w/handle & banjo BTW] is designed to mounted on "flat" (or, at least, "flatter") style handlebars, such as the ones found originally on all XJ-series bikes (except the XJ650 Maxim/Midnight Maxim, XJ750 Maxim/Midnight Maxim, or the XJ1100 models.....all of these models used the curvy buckhorn style bars). All other models use fairly flat handlebars, and thus the replacement HCP1808WO master cylinder will work on those bikes correctly; they leave the mirror mounted in the proper orientation.

c) thus the aftermarket HCP1808WO master cylinder is going to leave the stock mirror tilted at a rather crazy and semi-useless angle when installed on any model that had those curvy, "buckhorn" style bars, and we do not have a stock-style mirror substitute that "solves" this problem. About the only solution we offer is to use the "bar-end" style mirrors, which attach the mirrors to a mounting stem that fits inside the end of the handlebars (which requires modification of the grips by cutting away the rubber on the ends of them).

d) Also, on the XJ650 Maxim and Midnight Maxim models, the fluid outlet port (where the brake hose attaches), is facing "inward", towards the centerline of the bike (when the forks are pointed straight forward). The replacement HCP1808WO master cylinders have their fluid outlet port facing straight forward, and therefore your stock brake line has to be contorted to a rather odd angle to make it reach and fit this forward-facing outlet port. We do have available modified rubber or braided stainless steel brake lines for use of the aftermarket master cylinders on these bikes; their end fitting is rotated by the 90-degrees and extended by an appropriate length to allow it to attach to the aftermarket master cylinders properly."

Also check out Airheart's guidance http://www.airheart-brakes.com/pdfs/MasterCylinder_Selection.pdf

Thanks for the advice here man... I appreciate it... just wanted to say that..

 

[Ribo]

So I finally got the rear back together with new brakes....woot.... no more de-lamination or asbestos worries and with a new lick of paint and some cleaning it looks pretty nice I think... now my new headlight is due to arrive on Thursday allowing me one night to get the electrics sorted so I can ride it on Friday before I got to San Francisco for a week.... nice...

 

[zap2504]

Something to try while waiting for parts - take a side photo of your bike, import it into your PC and edit it using Paint. Try "painting" the seat sides/rear (everything except the pilot seating area down to the upholstery welts) with the same color as the tank. It will make it look more like a "standard" bike, and a little like a cafe. If you like this, you might be able to get some good vinyl dye and dye that portion of the seat cover as an interim while you decide what major modifications you might want to make to the bike.

 

[Ribo]

Thanks for the suggestion man, appreciate you taking the time. I may do that. In a few weeks though I plan to paint the tank and side covers black. Not sure what you mean by a "standard" bike?

 

[zap2504]

Not sure what you mean by a "standard" bike?

The Seca/Maxims all have more of a "standard" seating position (similar to the CB350/750 and many other UJM bikes) - sitting fairly upright, arms straight ahead (maybe slight angle depending..), feet almost in line with hips. Even though the Secas look a little more "sporty" and the Maxims more "cruiserish" they both have very similar ergonomics. Just looking for ways to take some of the "cruiserish" look out of the Maxim w/o great expense.

 

[Ribo]

The Seca/Maxims all have more of a "standard" seating position (similar to the CB350/750 and many other UJM bikes) - sitting fairly upright, arms straight ahead (maybe slight angle depending..), feet almost in line with hips. Even though the Secas look a little more "sporty" and the Maxims more "cruiserish" they both have very similar ergonomics. Just looking for ways to take some of the "cruiserish" look out of the Maxim w/o great expense.

Gotcha - thanks...

 

[Ribo]

She's back on the road with a new headlight and under tank wiring.. it's a bit magiver right now but I'll do until I get the custom harness for the winter rebuild...

Next up is the MC - that stock one is so damn big you could choke a donkey with it..

 

[Ribo]

Couple more photos from outside.. not looking too bad - kinda a cafe chopper at this point New tank and seat should fix that I think... I'm just having fun with this until I get to do a full stripdown over the winter. Without all that extra weight on the front it certainly makes a difference - this thing really files.. I must get the valve clearances checked though.... maybe I'll get time this week. At least I know the brakes are good now.