83 Yamaha XJ900 - Kit

dossbag · 09-24-2015, 10:30 AM

I used to have an XJ900 in UK before I moved to the USA, in fact I had to sell it before I moved. I always missed it as it was a fantastic bike, but I just couldn't find them over here.
I discovered the government blocked anything over 750cc to try and bolster the Harley industry, but 1,000 of these bikes were shipped over. Mine is number 71

Some guy had used it for racing, so it was set up as a racing bike. Then moved it on and the next guy took it all apart and then decided it was too much trouble to finish and put it up for sale.

I risked divorce and nabbed it hehe.. No contest.

Trailered it home and showed my buddy.. he thought I was insane.

But I saw the potential. Sorry if the pics are too big. Not sure how this will come out.

dossbag · 09-24-2015, 10:32 AM

I guess they are a little on the "big" side. I can't change them from work, but I'll make smaller when I get home.

This is how all the engine parts came... in separate boxes.

dossbag · 09-24-2015, 10:38 AM

I threw it together just to see what I had and what I needed.. Rear setts had to go, it had racing tires, racing shocks, no main stand needed back light assembly, controls and sensors had been bypassed. Not too bad really I picked up a lot of this from US eBay, but had to get a lot from UK because of the scarcity of parts here.

Here is me in England on one of my last rides on my original

dossbag · 09-24-2015, 10:39 AM

Here is the assembled bike - nothing really bolted on or functional, just that I wanted to look at what it would look like.

dossbag · 09-24-2015, 10:46 AM

Great potential!! And after a couple of months and a steep learning curve, I got the engine to fire on my 2nd try. Mainly because the choke wasn't on 1st time. It sounded rough but was a good sign that the beast had life

I sprayed it up to the British spec and added the trim. I'm really pleased how it came out. I got about 750 miles on it now.

Unfortunately a clutch stud snapped and destroyed all the clutch side, metal everywhere. I flushed all the bit's out and replaced everything and it's back on the road but as the back wheel locked up I dropped it and still have some cosmetic work to do. I love this thing. It is very quick for a 33 year old bike.
Thanks for getting this far

Jeff

Weldangrind · 09-24-2015, 12:25 PM

Very cool! Thanks for sharing the build with us. Did you spray it yourself?

dossbag · 09-24-2015, 03:40 PM

Yes I did, Thanks

Black Granite Metallic.
Standard clear coat on everything but Eastwood 2part epoxy (in a can) on the tank. I found better fuel resistance with that.

**cheesy** · 09-24-2015, 05:31 PM

Adjuster · 09-24-2015, 06:01 PM

Nice. You must know what your doing to be able to turn that box of pieces back into an engine.

/

Weldangrind · 09-25-2015, 11:52 AM

Quote:

Originally Posted by dossbag

Standard clear coat on everything but Eastwood 2part epoxy (in a can) on the tank. I found better fuel resistance with that.

That was my next question. Thanks.

SpudRider · 09-25-2015, 03:39 PM

You did a good job.

When you have time, please do reduce the size of the photographs.

dossbag · 09-28-2015, 11:05 PM

OK Spud all set.. refresh if still showing huge. Sorry about that.

SpudRider · 09-28-2015, 11:41 PM

Thank you.

The thread is now much easier to read, so I read it all again.

You did a very nice job.

Weldangrind · 09-29-2015, 12:44 PM

Much better. Thanks!

09-24-2015, 10:30 AM	#1
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	83 Yamaha XJ900 - Kit I used to have an XJ900 in UK before I moved to the USA, in fact I had to sell it before I moved. I always missed it as it was a fantastic bike, but I just couldn't find them over here. I discovered the government blocked anything over 750cc to try and bolster the Harley industry, but 1,000 of these bikes were shipped over. Mine is number 71 Some guy had used it for racing, so it was set up as a racing bike. Then moved it on and the next guy took it all apart and then decided it was too much trouble to finish and put it up for sale. I risked divorce and nabbed it hehe.. No contest. Trailered it home and showed my buddy.. he thought I was insane. But I saw the potential. Sorry if the pics are too big. Not sure how this will come out. __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
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09-24-2015, 10:32 AM	#2
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	I guess they are a little on the "big" side. I can't change them from work, but I'll make smaller when I get home. This is how all the engine parts came... in separate boxes. __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
	0

09-24-2015, 10:38 AM	#3
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	I threw it together just to see what I had and what I needed.. Rear setts had to go, it had racing tires, racing shocks, no main stand needed back light assembly, controls and sensors had been bypassed. Not too bad really I picked up a lot of this from US eBay, but had to get a lot from UK because of the scarcity of parts here. Here is me in England on one of my last rides on my original __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
	0

09-24-2015, 10:39 AM	#4
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	Here is the assembled bike - nothing really bolted on or functional, just that I wanted to look at what it would look like. __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
	0

09-24-2015, 10:46 AM	#5
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	Great potential!! And after a couple of months and a steep learning curve, I got the engine to fire on my 2nd try. Mainly because the choke wasn't on 1st time. It sounded rough but was a good sign that the beast had life I sprayed it up to the British spec and added the trim. I'm really pleased how it came out. I got about 750 miles on it now. Unfortunately a clutch stud snapped and destroyed all the clutch side, metal everywhere. I flushed all the bit's out and replaced everything and it's back on the road but as the back wheel locked up I dropped it and still have some cosmetic work to do. I love this thing. It is very quick for a 33 year old bike. Thanks for getting this far Jeff __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200 Last edited by dossbag; 09-30-2015 at 01:59 PM.
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09-24-2015, 12:25 PM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Very cool! Thanks for sharing the build with us. Did you spray it yourself? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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09-24-2015, 03:40 PM	#7
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	Yes I did, Thanks Black Granite Metallic. Standard clear coat on everything but Eastwood 2part epoxy (in a can) on the tank. I found better fuel resistance with that. __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
	0

09-24-2015, 05:31 PM	#8
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 5,984	__________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
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09-24-2015, 06:01 PM	#9
Adjuster Join Date: Dec 2014 Location: Deerfield Beach FL Posts: 1,410	Nice. You must know what your doing to be able to turn that box of pieces back into an engine. /
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09-25-2015, 03:39 PM	#11
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	You did a good job. When you have time, please do reduce the size of the photographs. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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09-28-2015, 11:05 PM	#12
dossbag Join Date: Jul 2014 Location: Michigan Posts: 162	OK Spud all set.. refresh if still showing huge. Sorry about that. __________________ 2014 Bashan Storm 250 Enduro 1998 Harley Davidson Fat Boy 1993 Suzuki GSX600F - Rebuilt 1995 Harley Davidson Chopper build from ground up. 1983 Yamaha XJ900 REBUILT! 1971 Triumph Daytona 500 - Restored 1987 Yamaha FJ1200
	0

09-28-2015, 11:41 PM	#13
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thank you. The thread is now much easier to read, so I read it all again. You did a very nice job. __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
	0

09-29-2015, 12:44 PM	#14
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Much better. Thanks! __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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