Cake's XJ 600 S

Every XJ is a project whether big or small. Tell us about yours.
User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Thu Apr 02, 2015 6:27 pm

I created this thread to share progress of my XJ. I won't be doing a big fancy project, but since I have learned a lot myself by seeing other peoples projects (big and small), I wanted to contribute to that too. I guess it will mostly be a lot of fixing various things that shows up (if not already present). It will also give me the opportunity to ask small questions not necessarily worth its own thread and most likely get help and ideas on how to overcome obstacles I might encounter.

Image

Okay, so I got the XJ late last year. This meant that I only had about a month of riding before winter and cold weather set in. It's now spring and I have had my first ride again. Overall the bike functioned and looked okay when I bought it, besides a very spongy front brake (which has now been fixed by simply bleeding the brakes) and some other issues. The paint on the plastics looks quite faded though – I think I will start trying to polish it and see how much that helps.

Engine clattering
The engine makes a rattling/clattering sound, but only when running low revs, so I haven't been too concerned about it. I'm not sure what is causing it. I only hear it when the engine is idling. Giving it a little throttle or a small pull in the enricher nob and it disappears (the engine sounds smooth once again). It kind of sounds like in this video (not mine) - try not to listen to the exhaust, but the underlying rattling. Perhaps it's difficult to hear if you don't know what you should listen for :). Could it be a loose cam chain? I don't think it's the famous clutch rattle, but I'm really not sure what's the cause. Anyway, perhaps I should try and record a video of it, so you guys can have a listen. Besides this sound, the engine seems to be running great, there lots of power and I'm pretty impressed by the 22 km/l (52 mpg) I'm getting. Didn't think it would do so well!

A little hard to start
It's a little hard to start when it has been standing still for a few days. I then have to use the starter for several seconds and if it has been standing for just a few hours i always have to pull out the enricher nob to start it. Actually I almost always have to use the enricher knob (unless just stopping and starting the engine for a short while). I don't know if this is normal, but I think it's a little slower and harder to start than it should be. I am thinking of replacing spark plugs and cleaning carburetors in hope that it will help. Will that make sense or is there other areas I should focus on? But again, once started and warmed up, it runs great!

Oil leak
Oh... and it is leaking a bit of oil. I think it's mainly from the cylinder head gasket and possible also somewhere in the carburetor heating system (european engine oil heated). From when I noticed the first bit of oil on the fins of the motor I guess I have ridden a little over 1000 km (~620 miles). Some oil have disappeared, but I have not had to fill up with extra oil yet. Anyway, I'll be having a mechanic take a look at it. I guess he can take a listen at the engine clatting sound at the same time. And obviously check the valve clearances if he replaces the head gasket.

I won't be having a mechanic do all the things I want to fix. But since I don't have an garage myself and I'm just at motorcycle novice, I'm a little limited in that way. Instead I'll do smaller isolated tasks. My first successful repair was replacing the rear brake light switch. Hardly difficult, but very time consuming, as I couldn't reach the connector without removing the side panel, tail panel and luggage rack with indicators :o. Some of the next tasks it will take a look at will probably be:
  • Rebuild forks with new seals and wipers
  • Reupholster seat
  • Replace spark plugs
  • Replace air filter
  • Replace intake manifold seals (all hard and cracked)
  • Mount another/bigger luggage rack (will be taking the bike for a 7 day trip in the summer with a friend, so will need to be able to carry extra stuff)
  • Build/connect a relay so I can wire up different electricals
  • Possibly try do something about the oxidized paint on the front fairing and side covers
  • Clean carburettors and synchronize them (but yikes it's a lot of small parts)
  • Replace fuel, vacuum and oil (for the heated carburettors) lines (they are a little stiff)
  • Fix steering lock, which isn't working at all
Well, actually many of the things in the Standard Maintenacne & Repair Items list :)

User avatar
Maxnettoz
One of the Regulars
One of the Regulars
Posts: 133
Joined: Sat Jan 26, 2013 6:44 pm
Region or State: Australia
Motorcycles Owned Currently: 93 XJ600S, 03 Honda ST1300A

Thu Apr 02, 2015 8:59 pm

Welcome aboard. There is more information in this forum than in a workshop manual. You will not be disappointed!!!! :thumbsup:
Sincere regards,
Maxnettoz

User avatar
radare
Site Founder
Site Founder
Posts: 8428
Joined: Mon Nov 07, 2011 12:42 pm
Region or State: Rocky Mountains
Motorcycles Owned Currently: '92 XJR600, '92 Seca II
Location: Denver, CO
Contact:
United States of America

Thu Apr 02, 2015 9:10 pm

You have a nice looking bike there, Cake. They don't get a lot of love in stock, faired form, so I'm glad to see you sticking with this one. Looks a lot like my red '92 when I first got it. They clean up well.

http://xjrider.com/viewtopic.php?f=72&t=6715

User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Fri Apr 03, 2015 6:31 am

I finished rebuilding the forks today. I started yesterday, so it took quite some time. Mostly because I had to find a good solution for propping up the bike. I couldn't find a plain metal rod to put through the engine mounts as I have seen others do. I could get a threaded rod though, but I didn't want to mark the engine mounts. I ended up using a 16 mm threaded rod covered in a 20 mm (outer diameter) plastic tube. The upper engine mount hole is just over 20 mm, so it was a very snug fit!
Image

This being my first major job on the XJ, I bought some torque wrenches. The yummi tools are: Wera 7000 A (1-25 nm) and Bahco 7851-200 (20-200 nm). That's a span from 0.7 ft. lbs. to 147 ft. lbs. I think that should cover every bolt on the bike :)
Image

While taking of the front fairing, a rubber thing fell on the floor. Does that belong anywhere?
Image

One of the fairing bolts head was rounded and the nut was stuck and missing its rubber thingy. Needless to say, it made the disassembly a little difficult.
Image

That wasn't the only problematic bolt. Look at this front fender bolt missing its head!
Image

I made a damper rod holding tool (like specified in 1Oldman's fork rebuild thread), but I was initially unsure of the size. 1Oldman say you should use a 5/8 th inch rod. Haynes says you should use a 24 mm size hex. 5/8 th inch is about 15,88 mm and I figured Yamaha mostly build the bike in metric measurements so I figured a 16 mm rod would do. And what do you know; the nuts for the 16 mm rod had an outside size of 24 mm. Perfect!
Image

This is why I wanted to rebuild the forks. Yikes!
Image

There is some pitting, but it's quite far up the stanchions, so i don't think it'll be a problem. The old seals wasn't leaky - just rusty!
Image

Bushing looks good. Some wear on the stanchion:
Image

Mhhh.... look at them non-rusty seals!
Image

User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Fri Apr 03, 2015 6:37 am

Maxnettoz wrote:Welcome aboard. There is more information in this forum than in a workshop manual. You will not be disappointed!!!! :thumbsup:
Thanks. I have already found the forum very helpful!
radare wrote:You have a nice looking bike there, Cake. They don't get a lot of love in stock, faired form, so I'm glad to see you sticking with this one. Looks a lot like my red '92 when I first got it. They clean up well.

http://xjrider.com/viewtopic.php?f=72&t=6715
I can't imagine that it is possible to make it shine as much as your bike. It looks really nice - like new :)

User avatar
Full Circle
Resident Expert
Resident Expert
Posts: 1022
Joined: Sat Feb 16, 2013 12:46 pm
Region or State: Ontario, Canada
Motorcycles Owned Currently: 07 FZ6

Fri Apr 03, 2015 6:54 am

That piece of rubber sits under the edge of fuel tank at the back, on the frame. There should be 2. One left side and one right side.

The bike looks really nice, and great job on the forks.

User avatar
Casper
Almost as Awesome as Murdock
Almost as Awesome as Murdock
Posts: 2342
Joined: Sun Feb 26, 2012 2:16 am
Region or State: Motor City (MI)
Motorcycles Owned Currently: 1994 XJ600, 2006 SV650

Fri Apr 03, 2015 2:15 pm

+1 to Full Circle

Rubber thing asked about snaps onto the lip of the gas tank on each side to give it a little more stability.
Men do not quit playing because they grow old; they grow old because they quit playing.

User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Sun Apr 05, 2015 4:39 am

Hmm... that's interesting, there only seems to be one. I guess I should try to find another one. Where do I get one? I have looked on ebay, can't seem to find one like it.

User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Sun Apr 05, 2015 4:42 am

Took the bike for a spin to the sea. The fork worked just fine.

Image

User avatar
cake
Lookin' Around
Lookin' Around
Posts: 69
Joined: Tue Sep 09, 2014 2:17 pm
Region or State: Denmark
Motorcycles Owned Currently: 93' XJ 600 Diversion

Mon May 04, 2015 3:13 am

As I wrote in the very first post, I wanted to be able to haul more luggage for longer trips. I already have a top box, so I guess the next logical expansion is to add some side cases.
Some time ago I bought a Givi N141 (Wingrack 2) and the appertaining mounting kit for XJ 600 pre-96 (Givi Y211). It might just be one of the last completely new sets in the world. The Wingrack it self is pretty easy to get hold of, but the Y211 mounting kit is close to impossible to get however, but here it is - completely new:

Image
Image
Image

Right side mounted:

Image

Mounting the Wingrack means that indicators cannot be located at their usual location because of the space needed for the side cases. Givi does a pair of indicators for the Wingrack called Z145. But I think they look clumsy, so I want to make my own indicator and mount assembly. The mount must fit in this gap (approximately 4-5 mm wide) and stick out long enough so the side cases can be mounted:

Image

Made a prototype to figure out the dimensions. Testing with a Wingrack 1 mount I had laying around - dimensions are the same:
Image

And so Wingrack Indicator Mount Mark I was created. Made of the precious material; plastic cutting board:

Image

This actually worked, but only for less than a day however, then one of the mounts broke off...
I bring you Wingrack Indicator Mount Mark II:

Image

This is made from aluminum, which I obviously should have used in the beginning. But as it would just be temporary until I got hold of the indicators I actually wanted to use with the rack, I didn't want to spend much time on making the holders. Anyway, this is much more solid.

So much for less clumsiness :):

Image

So here you can see why I think it is only a temporary solution anyway. While the Wingrack is not super pretty, I'm hardly getting any more style points for this look. I want to get some some small indicators that will make it possible to mount them much closer to the rack (and obviously, being smaller, they won't stick out as much). It does look less clumsy when the side cases (Givi E45) are mounted however (wide though!):

Image

Oh, yeah... and because the Givi cases are mounted using the Givi Monokey system, I need a new Monokey compatible top box...

Post Reply

Navigation:

  Search

  New Posts

  Unread Posts

  The Wall

  Gallery

  About Us


Call to Action:

  Forum Images

  Ride Relay


Cool Projects:

Predrag's Resto

Renegade's 93