XJ Build thread.

[fredintoon]

- - - I switched to an XS1100 triple tree so I can get round bars. - - -

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Hi Dogg,
XS11 'trees come in two reach lengths and if one of them's right for an XJ t'other one ain't.
I guess that as the XJ front axle is on the front of the fork like the XS11 Special the Special's 'trees are the ones to use.
But check before you test drive; changing the trail can lead to a surprise.

[Yard Dogg]

It looks like the bars mount in the same spot relative to the geometry. I should be alright. I didn't know about the difference in the fork though, noted.

[Yard Dogg]

Whoohoo!! I just scored an XS650 parts bike from my neighbor. I think it's a 70's bike. I've already found several parts that I will use on my XJ.

Handlebars, Clutch and brake levers with the master cylinder and a braided hose. I like em cause they are simple and in great shape. It has 2 K&N pod filters so now I have to decide if I want to use them.

The engine has excellent compression and looks very clean along with the exhaust and all the other major parts. It has wiring problems and no title. I'm thinking Fleabay dude! I can sell these parts and finance my XJ build. I can sell the parts for cheaper than the maggots too cause I have nothing into it. I can't believe the prices these people are asking, ridiculous.

Is anyone interested in a good XS650 engine?

I wonder if I can adapt the pipes, or maybe I should just sell them and buy new ones? Opinions!

[fredintoon]

Whoohoo!! I just scored an XS650 parts bike from my neighbor. I think it's a 70's bike. I've already found several parts that I will use on my XJ.

Handlebars, Clutch and brake levers with the master cylinder and a braided hose. I like em cause they are simple and in great shape. It has 2 K&N pod filters so now I have to decide if I want to use them.

The engine has excellent compression and looks very clean along with the exhaust and all the other major parts. It has wiring problems and no title. I'm thinking Fleabay dude! I can sell these parts and finance my XJ build. I can sell the parts for cheaper than the maggots too cause I have nothing into it. I can't believe the prices these people are asking, ridiculous.

Is anyone interested in a good XS650 engine?

I wonder if I can adapt the pipes, or maybe I should just sell them and buy new ones? Opinions!

Hi Dogg,
yeah, me, but the shipping costs and border hassle would kill the deal.
I should get my lazy arse in gear and replace all the leaking oil seals in the engine I have, right? The bike still runs good despite the oil trail it leaves behind it.
Unlike the XS11 where the only new pipe option is from MAC, MikesXS sells several different XS650 exhaust systems.
Nevertheless, a good condition XS650 stock exhaust will still sell for a good price and besides, those pipes only look like they'll fit an XS11 (close, but no cigar) and you'd still need 2 more pipes even if they could be bodged on.

[Yard Dogg]

Your only 941 miles away. We could smuggle it on a charter plane. Mexico does it to us all the time.

[Yard Dogg]

Time for a few updates. I'm done with the wiring except for a few minor details so I wanted to show it off. Here's how the headlight and handlebar area looks with the new gauge pods and all the controls plugged in.



I relocated all the pigtails that would normally be in the headlight bucket to underneath the tank. I will probably build an aluminum tray to mount on the frame and keep them tucked up off the motor and out of eye sight. I still need to install new wires in my coils so they are not mounted yet. Look at how small that wiring harness is now! Less problems down the road.



Here is the battery area. Hard to see, but the fuse panel is gone, and I took out the 30 amp fuse and soldered an inline chip fuse. The original main fuse made about 8 splices before it even reached the ignition, now it has 3.



I've installed Screaming Eagle mufflers cause my originals were broke in half near the collectors. I swear I'm not trying to be cool and loud, that's just what I found with the money I've got. I may have to baffle them more.



And here's how the bike sits today. I'm waiting on a bunch of parts so I'm piddling around on little stuff. I can't wait to fire it up.

[Yard Dogg]

Oh yeah, here's a picture of the Pod Mounts. All I did was cut the bolt tabs on the pods, and welded new ones on that would be spaced for the special triple tree. Looks close enough to factory.

[Nightengale]

i like it

Time for a few updates. I'm done with the wiring except for a few minor details so I wanted to show it off. Here's how the headlight and handlebar area looks with the new gauge pods and all the controls plugged in.



I relocated all the pigtails that would normally be in the headlight bucket to underneath the tank. I will probably build an aluminum tray to mount on the frame and keep them tucked up off the motor and out of eye sight. I still need to install new wires in my coils so they are not mounted yet. Look at how small that wiring harness is now! Less problems down the road.





Here is the battery area. Hard to see, but the fuse panel is gone, and I took out the 30 amp fuse and soldered an inline chip fuse. The original main fuse made about 8 splices before it even reached the ignition, now it has 3.



I've installed Screaming Eagle mufflers cause my originals were broke in half near the collectors. I swear I'm not trying to be cool and loud, that's just what I found with the money I've got. I may have to baffle them more.



And here's how the bike sits today. I'm waiting on a bunch of parts so I'm piddling around on little stuff. I can't wait to fire it up.

i do like the exhaust, how does it sound?

[Yard Dogg]

Uh...I've never started this bike. I will have the parts to fire it up next week. I ordered new mains and pilots, a K&N filter to cut and put in my filter bracket, a Harley Sportster seat, and a gas cap. Today I cut all the brackets off the rear frame tubes to clean things up. Then I'm mounting a chrome rear fender from an XS650, then welding brackets for a rack and smaller round tail light from an XS750. I'm making mods and trying to keep the factory appeal at the same time. I found some tear drop shaped running lights to use as turn signals to compliment the tank. It's going to look sharp in a cruiser way.

[Yard Dogg]

Today I got my front brake pads in the mail so I screwed around with things. I wanted to switch from the linked brake system to separated, the way I think it should be, but I wasn't sure how big my after market front M/C is. Well it's too small. I have a great big bulky front M/C from a 750 standard but I want to keep my smaller cleaner looking levers so I went back to the linked system. What the hell, I've never tried it, maybe it'll be nice. I don't plan on terrorizing the highway on this bike.

I'll have the parts to fire it up in the next few days, anticipation is killing me. I have fears, and little clouds above my head with an inner voice chiming in, "Will it start?"....."Will the rod go through the block?"....."Will it ring lock?" I hate this part.

[Yard Dogg]

Okay, I got to hear the bike today. I finally got the right main jets, set my fuel level, put the carbs on and it roared to life. At first it was hitting on 1 & 3 cylinders only. I came on here and found the correct spark plug wire order then it hit on all 4. I had to splice and extend the number 4 spark plug wire cause I'm using 2 right side coils.

The motor sounds healthy and the Screaming Eagles sound great! I love em. It has a deep throaty and loud sound to it, when revved it sounds like a race car. It's sounds real rough so I will attempt to sync them, but I'm sure it needs shimmed. The thing smoked out my whole neighborhood for about 10 minutes, so I shut it down and let it cool. Started it again, and no smoke. It must have been all the transmission fluid in the pipes from having to break the rings loose.

All I have left is to wire the lights, clean the gas tank, and a little welding for the fender mounts. I have a rack from my XS750, and a set of leather bags that will mount right to them. I can't wait til the 16th so I can get it registered and take a first ride.

[Yard Dogg]

On one negative note, my Virago tach will not work. I need to check on a Virago website to see how the tach sensor works. If I'm correct, our tach read in 1 revolution of the alternator, I have no idea what the virago does. I can always swap out the gauge face for the ones in my XJ gauge pods, probably what I'll do. I don't mind the black faces anyway, they're less intrusive when riding at night. So, I'll just do that.

[Yard Dogg]

I took a break from my bike for a short while but I'm back on it now. My car transmission blew up so I sold it and used the money to get my truck back on the road.

I have 2 days to get the XJ ready for my state patrol inspection. I figured out why the tach wasn't working. The virago tach reads from the orange wire that fires the number 1 coil. I should have put 2 and 2 together because the color codings are the same on the two bikes. After I hook the orange wire on the tach to the orange wire on the coil, it should work. Thank you mister obvious.

A bit of really bad news. I chemically stripped the paint off my tank, then hit it with a wire wheel and found 6 pin holes in the tank from the thick scaly rust inside. I tried to tach them closed but blew holes in it due to how thin the metal is after being rusted out so far. I have a real nice tank on E-Bay which I will pay for tomorrow but it won't be here in time for inspection. So I will have to temporarily mount my 750 Standard tank to the bike. It looks goofy as hell and sit's up an inch too high, but it will serve the purpose. This 750 parts bike has proven to be invaluable.

The things I have left to do.

1. Set the fuel level higher, tune the carbs.

2. Weld on mounting tabs for my rear fender, turn signals, seat, and temp gas tank.

I will post pics in a few days, first of the goofy looking gas tank, then after I install the real one. I think you guys are going to love my rear fender. I bought a trailer fender, cut it down, then added about 1 1/2 inches to the sides so it would look like a regular motorcycle fender. I looks great with the Sporty seat. I also bought some regular small eye shaped clear lens turn signals for it too. I can't wait to ride it.

[jwhughes3]

Sounds like good progress.

Better to find pinholes in the shop than on the road. This came up just recently on the XS SE Rally when the XS650 with us sprung a pinhole leak right before riding The Tail of the Dragon. Brent's epoxy putty saved the day of riding, but that will need a permanent repair.

John

[Yard Dogg]

I have an XS 650 tank for sale. Have him PM me. There's a few dings but very little rust.