1995 XJ600 Rejuvenation Project

Every XJ is a project whether big or small. Tell us about yours.
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Drapheus
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Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:41 am

(This is my thread from the other forums)

Aug 22, 2011

While trying to diagnose a couple issues on my '92 after the GA to PA trip, I stumbled across this beaute.

1995 XJ600 Seca II, 2,300 original miles, all complete! It's been sitting since 1998 and needs quite a bit of work as you can imagine, but I've got a good head start. At this point it needs:

Fork seals
Clutch cable
Carbs rebuilt (in progress)
Tires
Chain
Oil + filter

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This fairing was a little more intensive to get off than the '92
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Little windscreens...hmm
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Front fairing has a clean break. Perfectly fixable.
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The ignition switch still had that factory peely film. Nice!
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Nastiness
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Yikes
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There's probably some foul beast in there waiting to attack my hand
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Gotta go
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Dirrrrttyy
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This one should be salvageable
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What came out of the tank
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It's in decent condition
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The whole inside looks like that
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Had to grind off a link because I don't have the luxury of a chain breaker yet
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Before some washing
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After some low-pressure washing
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Better, better
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The foam on the bottom was crumbling, but the actual filter looked brand new
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Now for the carbs
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Back, foul beast!
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The throttle cables moved, so it was the carbs that were pretty gummed up
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The clutch moved, but the cable was stuck
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Gonna needs new booties
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Since the clutch cable was frozen, I had to remove the handle to get the cable out of there
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Ok, carb time
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Not bad, not bad!
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Pretty nasty, but workable
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And as you may have predicted, I broke a float tower. Clean break though so it should be repairable.
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:41 am

10ldman wrote:Drapheus, don't forget to flush out the fuel pump when you get ready to run fresh gas into the carbs. What you see in your tank and carbs is also in your fuel pump and filter.
Thanks for the heads up. I went ahead and just put the whole fuel assembly from my '92 on there, and I will clean out the new '95 pump tomorrow.

I found out it's a 1995 based on the VIN, too. It says 11/94 as the manufacture date on the VIN sticker, but it comes up in my insurance as a '95. I suppose that makes sense, because my '92 says 12/91 as the manufacture date.
Prafeston wrote:I forgot to add, this seems like an absolute steal for 200 bucks. The low mileage alone should have made it worth more than that...even if it has sat for many years!
It still hasn't really hit me yet. I was looking for a parts bike so I could combine the two and have one good XJ, but there's no way I can do anything to this one except restore it. :)

OK, got it started this evening with little trouble. There was a little white smoke coming out of the right exhaust, but it stopped after a couple minutes of idling. Still, there's lots of work to do. Fork seals are the next task, then gas tank, brake caliper rebuilds/pads, tires, chain, and fixing the cracked front fairing.

The 95 (R) sits a little higher than the 92.
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It feels taller just sitting on it.
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Maybe I should give them names?
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First things first, change the oil. I have an oil catcher but always seem to get oil all over the place.
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Drink....yeess driiinnkkkk
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Original filter. Wow.
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Did just a hair of cleaning on the carb bits today. The actual rack is really stuck up. Gonna have to split the whole thing because the butterflies are very hard to move, even after soaking in Pine Sol all day. I'm just going to use the '92 rack for now.
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I soda blasted them puppies
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I then put the fuel pump from my '92 into the '95, changed the plugs, and turned the engine by hand a couple times.
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Well I'll be darned. It idled very smooth! What a relief.
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A little bit of white smoke blessed the right exhaust. Went away after a couple minutes of idling. I haven't even tested the compression yet, honestly.
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Protip: Don't get your pants stuck in there like I almost did.
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
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Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:42 am

10ldman wrote:Isn't it nice to be able to swap around parts when you have two? :lol: After a year and a half I'd collected a fair amount of critical spares for my '93 so when the '94 came along I had just about everything I needed already. Another bennie is that the '94 has a '93 vin date on it so, technically, I have two '93's. The out come of this is that I can swap the license plate and registration over to the '94 if I want to take it for a spin, who's to know? (shhhh, The '94 is still registered non-op. ) :lol:
Yes indeed! I plan on doing the same plate swapping at least while doing some test rides around the block. The '95 came without a title, but it's fairly painless effort to get one here in GA and I'm going through that process right now.

Yea you guys are probably right about the initial smoke. It wasn't thick like oil smoke and didn't smell like it. My theory is that whenever the engine stopped for the last time, the smoking cylinder was the one who ended up with the open intake valve. There was probably moisture or something in there.

And I'll consider all options for names lol :P I call the '92 "Xavier" right now because he has wheels and doesn't do anything. You know, from X-Men?

Maybe I should call the '95 "Magneto" lol
'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:43 am

Got a little work done on the gas cap during my lunch breakery

With the weather seal removed
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Unacceptable!
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Disassembled
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Oh this will not do
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After some soda blasting
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Assembled. There's some pitting in the metal, but it's not like people are looking at the underside of my gas cap as I'm riding down the road. Or are they...
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And finished
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:44 am

tehninja wrote:What's your soda blasting setup?
I have a home made blaster with an air compressor @ 80 PSI

This is v2.0
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Was having feed issues so the design needed to be re-worked
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You can't really see it, but the top of the feed tube is blocked with a little hot glue, and then a series of small holes were drilled in it so the soda isn't being fed through from one single spot.
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
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Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:44 am

Disassembly and inspection progress

These bar ends will polish up nice. Going to paint them black.
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The XJ gods are cutting their wrists
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Yes, there will be rust. But I need to make sure none of it is compromising the structural integrity of the chassis.
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I just cannot wait to soda blast this
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This will clean up nicely. I'm so glad it has factory black wheels.
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On the morrow, these specimens will have the shazbot soda blasted out of them
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Isn't the nut normally on the right side? Interesting.
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Oh dry rot, how you depress me so
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Unacceptable
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I don't need rust infecting my sprockets, thank you
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When I did the fork seals on the '92, it was quite a challenge keeping the front propped up. This time, I'm going to try putting a metal bar through these here engine mount holes and jaquing it up from there.
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Exhaust nuts, screaming for some polish.
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It's getting there. Pretty excited!
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:45 am

katastrefo wrote:Great thread here. If I were you, I'd drop the $100 on a lift. It'll make your maintenance a lot easier, plus the bike sits up higher so you're not crouched over all the time. I think I got mine at a pep boys, but you can find them everywhere on the cheap.

http://www.harborfreight.com/1500-lb-ca ... -2792.html

Only $80 if you find one of those 20% off coupons.
Might go get one of those this weekend. Thanks for the link!
swartz77 wrote:Looking good, can't wait.

My nut is on the left side....er.... :shock:
You should probably have that looked at..... :P

Cleaning up more specimens

Before some blasting
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After some blasting
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It makes the rubber booties look brand new
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The exhaust nuts were rusty, but not no mo'
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:45 am

Today I finally got the carb bodies separated. Man are they a mess. Even separated, the butterflies are sticky and hard to turn. But those aren't going back this bike, anyways. I'll have time to do a real good job on them.

I don't think I've ever said it publicly, but levels of dirtiness like this keep me up at night.

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This is acceptable

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Once the fork seals get here, I'll start the work on the front end. The forks are black from the factory and still in good condition. They should polish up superbly without paint.

After the front end, I'll move to the top and do/clean/paint/inspect the handlebars, controls, and levers.

I still need to get some tires. Might get Shinkos for this one, too.
'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:46 am

Couldn't get that lift this weekend :evil: Maybe next week.

Some progress on the front today. These forks will be beautiful.
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The bar-through-the-engine-mount worked pretty well. Very stable.
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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User avatar
Drapheus
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Posts: 1889
Joined: Mon Nov 07, 2011 2:42 pm
Region or State: North Georgia
Motorcycles Owned Currently: 95 XJ600, 92 XJ600
Location: Atlanta, GA

Tue Nov 15, 2011 10:46 am

The butterflies on the carbs would hardly move -- serious gunkage contaminating the shafts.

The throttle shaft seals were "gooey" and keeping the shaft from turning freely. Atrocious.
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Look at those things. Despicable.
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My gawsh did I have quite a time trying to get the choke plungers out. Had to resort to a propane torch to melt whatever fluids had hardened in there.
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I carb cleaned my eyeball, and it hurt really bad.
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'92 XJ600 - 50k | '95 XJ600 - 5k
Andrew Long Motography
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