New Member, New Vision Project. help? (lots of pics)

[diablo_man]

hey guys, my account finally went through! :D

so i picked up a 1983 xz550 with fairing a few weeks back(41,000km/25,000miles), and have been slowly taking it apart. ive got some pictures for you down below, and also some technical questions.

I picked it up non running, decent condition, engine turns over, isnt seized.. The starter doesnt work, the button doesnt engage the starter motor (or do anything, i suspect electrical issues) and i took my battery charger and jumped the starter. It spun up, but didnt engage the engine at all. sounds like it was just spinning, plugs were out.

apparently there is a starter clutch issue? could this be the cause?

Also, upon turning the handlebars side to side, i noticed a "notch" when the wheel was pointed forward. it wasnt a smooth transition from left to right, it seemed to settle in the center. Headset bearings?

also inside of the gastank is a bright red.i suspect heavy rust.

i also just ordered the Haynes.

the day i bought it.



















It also has the aftermarket mac exhausts, which upon closer inspection have a millimeter sized hole in the front header.

here is what it looks like now.



cracked old rubber, fuuuuun







hopefully i can set it up with either a large round front headlight, naked style, or two smaller ones like the speed triples. but still be able to swap to the fairing without too much difficulty for trips. but first it has to engage the starter, turn over, start, run and then handle half decently.






so i could either post the pics full size, which are massive, or these nonclickable large thumbnails.
here are the links to the full images, if you are interested

http://imgur.com/KEInh.jpg
http://imgur.com/qmjuI.jpg
http://imgur.com/gwd8A.jpg
http://imgur.com/I4mg1.jpg
http://imgur.com/9ll0L.jpg
http://imgur.com/ylEVB.jpg
http://imgur.com/V89mM.jpg
http://imgur.com/srW5z.jpg
http://imgur.com/GYnRB.jpg
http://imgur.com/z26r2.jpg
http://imgur.com/SVKKF.jpg
http://imgur.com/7MoO7.jpg

[fret not]

That is a handsome bike, especially for as old as it is.  Nice.

[diablo_man]

also gonna need a mirror, turn signal bulbs and a new windshield.

hehe thanks, wish it ran as good as it looks.

[Tiger]

 :) Hi and welcome to your new and extended family... 8)

Nice 'Canadian '83' you have there buddy...Where are you located??

The carb' manifold boots can be replaced, if badly cracked, or repaired using 'Liquid Electrical Tape'...

The non working starter could be starter button switch unit needing a good clean out, a bad starter solenoid, or...... ???

The starter clutch is an easy fix...should take you about an hour or so to do...if you have all the tools... ;)

Tapered steering head bearings will cure your steering problem. They are available from... www.pyramid-parts.com You can also get fork seals/dust covers, brake pads, front and rear wheel bearings from the same supplier, (Its who I use).

Make sure that its rust and not a liner that is in your gas tank!!!

Signal indicator bulbs are #1156, rear stop and tail light bulbs are #1157, 'idiot lights' are #194 and the headlight is an H4...all should be available from your local auto store, Walmart, etc...

                     8).......TIGER....... 8)

[Lucky]

How are the tires?
the windshield can be polished out if it's not cracked thru.  aftermarket replacements are available.

swaping the fairing on & off isn't something you'll want to do on a regular basis. you have to drop a fork tube to get one of the braces out, the headlight mount is different you have to move the turn signals, etc.  the fairing itself is nearly unobtanium...

your probably going to need a starter clutch replacement.  usually the mounting bolts for the clutch loosen up & need to be replaced, the clutch slips.  if yours isn't catching the crankshaft at all, it's probably cracked.  someone here will have one.

Welcome & ask all the questions you need.

--Lucky

[diablo_man]

:) Hi and welcome to your new and extended family... 8)

Nice 'Canadian '83' you have there buddy...Where are you located??

The carb' manifold boots can be replaced, if badly cracked, or repaired using 'Liquid Electrical Tape'...

The non working starter could be starter button switch unit needing a good clean out, a bad starter solenoid, or...... ???

The starter clutch is an easy fix...should take you about an hour or so to do...if you have all the tools... ;)

Tapered steering head bearings will cure your steering problem. They are available from... www.pyramid-parts.com You can also get fork seals/dust covers, brake pads, front and rear wheel bearings from the same supplier, (Its who I use).

Make sure that its rust and not a liner that is in your gas tank!!!

Signal indicator bulbs are #1156, rear stop and tail light bulbs are #1157, 'idiot lights' are #194 and the headlight is an H4...all should be available from your local auto store, Walmart, etc...

                     8).......TIGER....... 8)

Im located in British Columbia, Canada.

I've got plenty of wrenches and sockets, but no Vision specific tools yet.
yeah, havent really gone through the bike with the electrical tester yet, it has been modified a bit.

Is it a difficult procedure to install new tapered head bearings?

hehe, thanks for the parts numbers! BTW, i have no particular need to restore the bike 100% stock, so if any other generic part or something from a different bike works as good id be happy to hear about it.

How are the tires?
the windshield can be polished out if it's not cracked thru.  aftermarket replacements are available.

swaping the fairing on & off isn't something you'll want to do on a regular basis. you have to drop a fork tube to get one of the braces out, the headlight mount is different you have to move the turn signals, etc.  the fairing itself is nearly unobtanium...

your probably going to need a starter clutch replacement.  usually the mounting bolts for the clutch loosen up & need to be replaced, the clutch slips.  if yours isn't catching the crankshaft at all, it's probably cracked.  someone here will have one.

Welcome & ask all the questions you need.

--Lucky

The tires arent cracked, but do look kinda worn out along the center. need replacing, but they will do until i have the bike running and i can put it around, check out whats wrong.

dang. well ill probably keep the fairing on then. out of curiosity, if i swapped it out, or even just the lower fairing section, are there any members here who might buy them? and for how much? that might support my bike projects :P

the windsheild has been cut down to its current size and has a small crack through it, probably total junk. got a link for a new one?


And is it possible to repair the pinprick hole in the front header? can i get a new(or good condition used) header from Mac?

[Re-Vision]

Search under "replacement windshield" and you will find several sources. www.clearviewshields.com/prod.htm 

Depending on condition of fairing lowers I would definitely have an interest.    BDC

[Mike Jacobs]

the windsheild has been cut down to its current size and has a small crack through it, probably total junk. got a link for a new one?

If the crack is in fact small, and not interfering with function, you can "drill out" a crack in hard plastic (acrylic, plexiglas, lexan etc.) by making a circular hole at both ends of the crack which relieves stress to prevent the existing crack from propagating further.  But you probably already knew that.   ;)

And is it possible to repair the pinprick hole in the front header?

If like-new appareance is not an issue, why not just take it off the bike, and haul the header down to a local auto muffler shop?  Any competent welder ought to be able to fill in a 1 mm pinprick hole in an exhaust header, and if they're careful of appearance and don't "go too far" the repair might not even be noticeable ot the casual eye.   I'm assuming these pipes are not specially treated or coated with something, which may make the above suggestion worthless though.

[Porpoise_of_doom]

Gday Diablo, and welcome. You've got yourself a bargain there and a great start to what will be a great project. I'm in a similar boat to you, except instead of buying one complete bike, I bought 2 times 80% bikes and a couple cartons of bits. Look forward to seeing future posts, keep the photos coming!

[diablo_man]

So, this project is looking less and less likely for me to complete. I dont really have anywhere to do all the work on this, and most importantly, getting this thing titled is looking like its gonna be beastly. There have been a few titled bikes around here with more minor work needed(aka, already running, with some issues) popping up at good prices, but i cant have two projects sitting around and cant afford either.
Once my manual comes in, im gonna inspect the couple trouble areas in this bike, but if there is a lot of work involved, and then all the titling garbage i think id be better off to part er out. Now that my dad and friend have bikes, im seriously jonesing for a running bike, rather than a depressing pile of parts :(

So im considering parting this all out and I'd give you guys the first shot at it.
It is an 83, so a lot of parts could be upgrades for you guys with 82's. Namely the fairing, different clip ons, carburetors.
Most of it seems to be in pretty good condition.

Im on the west coast of BC, so consider your proximity and what shipping parts could cost. Any parts here you guys might be interested in? I can provide better quality photos.


feel free to try to convince me otherwise though ;)

[Re-Vision]

We know the folks here will help you any way we can to get your Vision rolling, you alone know whether you want to put the effort into your own bike. I'd recommend that you take advantage of an opportunity to learn your Yamaha and take pride in a good bike that you put on the road. If not, I'm still interested in good fairing lowers.    BDC

[The Prophet of Doom]

Don't be a baby.  I did my entire re-build with no garage right through a winter (which would be like a Canadian spring  ;D).  I didn't work on it when snowing, but if it was sunny, I'd take off the tarp and do a bit, or remove parts and work on them in the living room or kitchen then put them back on next session.

Windscreens from godiva.co.nz - good prices and they ship worldwide.

The steering head bearing swap is a piece of cake - takes maybe 3 hours.  The only tools you need are some pipe, a punch and a hammer.  Just unbolt and slide out the forks, then drift the bearings out with pipe and hammer.  Drift the new ones in using the old bearing to tap.  Then bolt the forks back up.  Use the punch for the castle bolt.

[diablo_man]

lol, dont forget the bike didnt come with any papers, or title. its a crapshoot if i could ever get it road legal and titled, running or not.

anyways, i havent given up on it yet. i think the Titling process, or lack thereof is gonna be what ticks me into parting it out or not.

[iain]

roro [rohan] you have such a way with words [dont be a baby] that would inspire me to get out there in the rain and snow and work on my bike..
Iain
NZ

[Lucky]

now if you 'downunder' types would spend as much time on your bikes as you do your avitars....wait...nevermind!  :D :D :D

[Re-Vision]

It shouldn't be too difficult to get a clear title if the bike hasn't been reported as stolen, take the VIN to the courthouse and have them check it out.     BDC

[The Prophet of Doom]

roro [rohan] you have such a way with words [dont be a baby] that would inspire me to get out there in the rain and snow and work on my bike..
Iain
NZ

Iain I bet you would do more work on your bike if it had a pair of breasts and a nice arse.

[kev10104]

That bike looks familar!Welcome and you will enjoy her soon enough.

[diablo_man]

Iain I bet you would do more work on your bike if it had a pair of breasts and a nice arse.

Only so much he can polish the intake and exhaust ports...

[diablo_man]

Good news for me, bad news for my bike. looks like i got a sweet job in a different city, but wont have any storage space for this bike, and my dad isnt too interested having 3 of my project bikes rusting at home.

With new job i should be able to afford a reliable bike for daily driving, and i have a 1970s kz750 project for tinkering on, modifying and having as a classic eventually.

I know you guys fall in love with this bike, and maybe if i had ridden one i might have, but right now its just a pretty pile o parts. I've had my fun with difficult to find parts and tricky machinery(1984 XL600R with the twin carb setup, was a nightmare)

so likely, unless i find a buyer for the whole thing nearby, ill just be taking this apart when i can as a mechanic lesson, and selling some of the parts to make my money back on it.

trouble is, i dont know what is worth shipping, how far any of you are away, whats a fair price for various parts, etc?

aside from the guy wanting bottom fairings, any interest or price suggestions?