XJ 750 Mod project

[wingnut]

Yep I have a set of those on the XS400. Love them for short rides.

[wingnut]

Update

All wiring has been sorted and everything works. She runs Now its time to fab the parts for the XS front end. Looks like I will need to source the brake line manifold from a 1100 special to make thing fit under the chrome cover for the lower triple tree. I'll post pictures Sunday

[jetmechmarty]

Does this mean you're using those Weird Harold brakes?

[wingnut]

Its coming along

Got the front end mostly sorted out. Used the upper triple tree from a XJ650, which had been exposed to 20 min on my buffing wheel, the fork ears and lower triple tree cover from a XS 750. I was able to retain the air fork set up by cutting the top off of the fork ears and still use all if the rubber and washer hardware. I don't believe I'll have any vibration issues with the head light. The headlight bucket is from an XS1100 and I chose it cause it has 3 holes to pass wires and connecters thru, just made life easer. Gauges are from a 83 XJ 650 cause I need an electric tack. The turn signals are from an XS, along with a set of buckhorns we had in stock, LH control from the XJ750, RH control is from a XS400. Still need lower brake lines from an XS11 along with the double stack banjo fitting. Also have to fabricate a bracket for the headlight height adjustment bracket.

Marty there are no weird Harold brakes on this rig. This bike weights 375 from the factory and even with the drum on the back and smaller disks this thing stops better than any of my other michines.

[wingnut]

Thought I'd post a before picture. This was taken just after the fire was put out

[wingnut]

Progress report, got the turn signals mounted and working. None of my instrument lights worked and we had some issues with the safety system. I had to hunt down a 7 wire diode block which was missing from the 650 harness. Haven't had it together enough to check the head light function but one light is on all the time and that's the low oil level light. Come to find out that the xj750 oil level sensor is electrically opposite from the unit used on the 650. Changing it out turned into an act. Ended up dropping the oil pan just to get at the wireing. This system was not the best idea the little guys from the raising sun ever had. i rather have a pressure warning system. The sleeve on the wireing was very brittle from all the heat cycles so I'm going to have to repair that. The SS hoses for the front brakes are here from China. $19 for these and they are of very good quality. Time will tell on how well they hold up, I will keep an eye on them. Still waiting for the banjo bold to finish up that system. Did get some buffing done on the side cases.

[wingnut]

So as I was changing out the low oil level switch I had to drop the oil pan to get at the wiring. I found lumps of coal in there. Seems as the primary chain guide is coming apart. Engine is coming out of the fame this weekend and a case split will be done. I'll take pictures.

[wingnut]

Lump of coal

So I found the lumps of coal in the oil pan that are what is left of the hyvo chain guide. This is just what I got out of the pan Once I got the cases split I found more. As you can see there was nothing left but the tab under the mounting bolts. The case split went very well and everything inside looks good with the exception of the guide. New part is on the way and I plan on reassembly with just replacement of the few orings involved.

[wingnut]

Well the hyvo chain guide was replaced and everything else looked really looked good. So it went back together. I'm going to do a valve clearance check before I pit it back in the frame.

[3Phase]

That's a nice save with the chain guide!

It all looks great, just take your time setting up the ignition and valve train right so you don't chase your tail all over creation after you fire it up and try to tune it.

.

[wingnut]

Checked the valves and all is well. Also checked the cam timing which looked spot on. Touched up the paint on the frame and we are ready to put the engine back in.

[wingnut]

Engine is back in the frame. So I put the carbs back on which were working fine when I removed them. Hooked up the test tank and turned the fuel on. It started raining fuel from every joint on the fuel tee and all the manifold joints. WTF!! It was good when I removed them. Oh well, off they came and I replaced the orings. I needed the practice R&R carburetors I guess Anyway the first start went good. No drama or oil leaks. Test ride without the tank or seat was different. When I went to shift from what I thought was first I found that with these rear sets you can put the shifter on upside down resulting in a 1 up 4 down shift pattern. That got my attention pretty quick. Figured that out and it seems the case split accomplished the mission and no other damage. Now I'm just chasing electrical gremlins. No headlight is the last thing and I'm close to getting it working. Had the new son in law come down and get his first intro to chrome and aluminum polish. Its looking pretty good. Reworked the side covers and will install the new seat cover this weekend while the tropical storm keeps us in doors. Once we get dried out it may be time for the 50 mile road test and finial tune.

[wingnut]

So I have put 150 miles on the bike. Glad to report all is well. Have to get the seat recovered and find a XJ750 tank as I'm using one of my 650 tanks and 2 quarts means a bunch more miles. So if anyone has one there want to part with let me know.

[MPittma100]

XJ750 Tanks

So I have put 150 miles on the bike. Glad to report all is well. Have to get the seat recovered and find a XJ750 tank as I'm using one of my 650 tanks and 2 quarts means a bunch more miles. So if anyone has one there want to part with let me know.

Here are several:

http://www.ebay.com/sch/i.html?_odkw...tank.&_sacat=0