Time to make the Keeper

[BA80]

Guess I'm missing why you'd want to do that in lieu of the XJ's electronic ignition system?

it's easier changing the mechanical parts than figuring out the rewire.

[crazy steve]

Guess I'm missing why you'd want to do that in lieu of the XJ's electronic ignition system?

The problem is also availability of the XJ-specific parts besides the rewiring issues. The '78-80 XS bike ignitions used all the same electronics, with just the mechanical/vacuum advances changed each year. In '81, the mechanical advance was moved inside the TCI, with only the vacuum advance still 'mechanical'. So you now have a one-year-only TCI box, no mechanical advance on the motor, and all the rest of the parts the same. In '82, the vacuum was moved to inside the box too, but now all the parts are unique one-year-only bits with no compatibility with the earlier parts.

If Bartman only has the '82 motor (not the full wiring harness), his cheapest/easiest way to use that motor in the '78 bike is to switch the ignition/charging systems on the motor to the '78 parts EXCEPT for the '78 mechanical advance. For best results, what he needs is the '80 advance. This will be found on motors with serial numbers starting with 3H5, 3J6, or 4H3 ONLY. The part number stamped on this will be 3H5-10/131-02.

[timktm]

I have an 82xj harness if needed
Tim

[crazy steve]

You can't swap the XJ harness over to a XS without some serious modification, it's actually easier to alter the XS harness.

[Bartman]

So last night I pulled everything off of the frame. It just needs a good degreasing and some fresh paint.

Update on the blown motor, the top of the exhaust valve stem was stuck in the head. So if broke down about an inch and that is why it ran lean and burned a big hole in the top of the #3 piston. The cylinder isn't even damaged! Still won't use it but have pulled most parts for spares.

I do have a 3J6 motor sitting in the barn. As Crazy steve mentioned, I will pull that mechanical advance and use it in the XJ motor.

The XJ frame, motor and wiring harness are good. Not any components attached to the wiring harness though. AND I won't chop that good harness up. Wiring harness and the frame will be for sale when the motor is pulled.

I go slow and since this is a project, I will update as I move along.

[Bartman]

If the rule of thumb is to clean the carbs three times, how many times do you clean the frame before you paint?

Saturday I sprayed degreaser on the frame, kick stand, swing arm and wheels several times during the day and then took in the truck bed to the car wash. Used the tire cleaning fluid and then sprayed clean.

Tonight I took a stiff brush and a bucket of Dawn dish soap and scrubbed again.

I thought that my next thing would be to hold the frame up with the tractor and spray from top to bottom with brake cleaner.

[Bartman]

My buddy at work took the swing arm and various parts to dip in an acid bath before painting. As I figured, the frame won't fit into his container.

He has a bearing press, so if my wheel bearings come in before this weekend My plan is to go there and get them pressed in.

I pulled the old tires, inner tubes and hold down clamps off the wheels. I believe that I have read that this wheel is the same as my 79 except for the extra holes for the hold down clamps.

IS THIS CORRECT? I CAN run tubeless tires?

I was thinking about tapping the two holes and putting bolts on the inside screwing out with seal washers. Other ideas?

I still haven't been able to pull the stator wheel yet! I am hoping my buddy has a 16 mm puller.

[bikerphil]

Correct, the rear rim is the same as a tubeless, seal off the holes and you can use the rim without a tube. I have done this and have ridden many miles with no issues. IIRC, I used an NPT plug which is tapered for a tight fit, and tapped the rim holes and used RTV sealer on the threads.

[Bartman]

Sat. I got all wheel bearings changed and both wheels shot blasted. Tonight I was able to get the donor motor out of the 82 XJ frame.

Anyone want a good XJ frame, wiring harness, forks and both fenders for a good price? Surely a bobber person would love to get this....

So, before I take off the electronic pickup, any words of advice. I am assuming that it won't stay at TDC as I try and loosen bolts!

[HalfCentury]

Sat. I got all wheel bearings changed and both wheels shot blasted. Tonight I was able to get the donor motor out of the 82 XJ frame.

Anyone want a good XJ frame, wiring harness, forks and both fenders for a good price? Surely a bobber person would love to get this....

So, before I take off the electronic pickup, any words of advice. I am assuming that it won't stay at TDC as I try and loosen bolts!

Does your XJ1100 donor have a left exhaust?

[motoman]

Apologies for slightly sidetracking this thread, but was interested to see the xj alternator has a higher output than the xs. Is the xj unit a straight forward swap over with the xs?

22amp as opposed to 28amp.......not enough difference to be worth the hassle of changing IMO. Scott(3Phase) put the XJ alt. setup on his 80G a couple yrs. back since he already had it and wanted to just use the higher amp alt.......just because and bored would be my guess since he has no additional lighting on bike.

[Bartman]

Sorry Half,
The exhaust went to Kurt the other week when he bought the wheels.

[HalfCentury]

Sorry Half,
The exhaust went to Kurt the other week when he bought the wheels.

It went to a good home! I am attempting a tin-can and clamp hack on my cracked exhaust.

[Bartman]

With all of the good welding that Kurt is doing with those HD exhaust, he might not need them.

[Bartman]

When I pulled the oil pan off the 82 Donor motor I found a small washer and snap ring laying in it.

Tonight I pulled the clutch pack out and found that the small upper oil pump gear was missing the washer and snap ring😃