Xj600 Diversion Project

[Nope.]

Ok, so I picked this up from a member on here yesterday. I got it quite cheap so I'm going to try and get it running. If it runs and is viable then I'll fix it, MOT it and get it on the road. If it doesn't run with some basic fiddling then I'll break it for parts and make back my costs.

Today I set about stripping it down. The first thing I noticed is that this bike is actually quite nice to work on, everything is easily accessible and has enough space around it to get your hands in. The last bike I thought that I'd ever like was a Diversion but I guess I was wrong!

After getting the rear fairings and the tank off the next thing I noticed was the black petrol that had obviously sat in there for quite a while. I think the tank might need a good clean and de-rust. After taking off the tank and the airbox I noticed the rather strange downward pointing carb arrangement and rather strange fuel line system.

https://sphotos-c.ak.fbcdn.net/hphotos-ak-ash4/427644_10200434049393099_1884233418_n.jpg
https://sphotos-f.ak.fbcdn.net/hphotos-ak-ash4/399991_10200434048793084_1953473562_n.jpg
https://sphotos-g.ak.fbcdn.net/hphotos-ak-prn1/75377_10200434048833085_667070632_n.jpg
https://sphotos-a.ak.fbcdn.net/hphotos-ak-ash3/541027_10200434049313097_600748857_n.jpg

After the carbs were off I put them to one side ready to be stripped down and cleaned out:

https://sphotos-g.ak.fbcdn.net/hphotos-ak-ash3/553087_10200434049993114_1574629372_n.jpg

The previous owner said that the starter motor didn't work so I grabbed a spare car battery and bypassed the stator solenoid, sure enough the starter motor cranked the engine over. One less thing to buy!

https://sphotos-e.ak.fbcdn.net/hphotos-ak-ash3/74309_10200434049433100_1564772941_n.jpg

https://sphotos-f.ak.fbcdn.net/hphotos-ak-snc7/318027_10200434049713107_951345623_n.jpg

https://sphotos-d.ak.fbcdn.net/hphotos-ak-ash4/388249_10200434049793109_214634829_n.jpg

The next step is to strip down the carbs and clean them out. I'll need to use an impact driver to remove the typical mikuni cheese head screw and then I can replace them with stainless steel screws.

So, so far there is a small list of things I'll need to buy to get the bike road legal:

* A front tyre
* A new front brake caliper
* A set of fork seals
* Some fork oil
* Maybe a stator solenoid
* Possibly a battery
* A speedo
* A full exhaust system (Since it doesn't have one at all. I might make one out of copper pipe for lulz)
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Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

[sidewinder]

Looks like a cool project you have there love my little divvy .a good thing to do whilst you have it apart is to give the breather pipes a good clean out they build up condisation which turn to a white gloop.which then causes the bike to piss oil out when you stop the engine
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"Nitrous is like a cheap hooker, you want to hit it but are scared of the consequences

[Kickstart]

Hi

Those carbs are a pain. The vacuum fuel pump is a bad joke by Yamaha. The pipes between the float bowls seem to do a good job of allowing fuel to migrate from the right hand carb to the left hand carb while the bike is parked on the side stand, so the left hand float bowl over flows (into the intake.....).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[mgh0]

[Nope.]

Thanks for the tips guys, I'll be cleaning out all of the fuel carrying pipes, taps and joints since they're all filled with a mixture of an inexplicable black liquid and water.

Today I started stripping the carbs down. All I can say is thank god for my impact driver and dremel! I don't know why Mikuni feel the need to use screws made of cheese but I've never come across a Mikuni carb with standard screws that have been easy to remove. All of the screws in these will be replaced with copper slipped stainless steel screws. I managed to remove 6 of the 16 screws without the need for the impact driver, of the remaining 10 I had to use the dremel to cut slots in two and then use the impact driver to remove them. Not my worst Mikuni experience but certainly not the best!

Once I got into the carbs I was surprised to find all but one jet blocked. Perhaps this is due to the douse of carb cleaner I gave them the other day but the jets seemed remarkably clean. The floats and float bowls on the other hand were a different story, they were both covered with what appeared to be limescale, suggesting that there has been waster sat in these float bowls for a while. After a bit of carb cleaner and a toothbrush I cleaned most of it off but I'll be putting the float bowls in an ultrasonic cleaner tomorrow. The carb bodies are incredibly dirty but I don't particularly want to split the bank to clean them unless I absolutely have to for some reason.

Since the float bowls were in such a bad way it looks like I'll have to replace the float bowl gaskets, and whilst I'm there I may as well do the O-Rings. I've found one supplier of the gaskets in the USA but I can't seem to find any in the UK yet. I'm going to give yambits a ring tomorrow but if anybody knows of a supplier I'd appreciate their details.

Here are the carb photos, I only took photos after I'd done a bit of cleaning since I didn't want to get dirt on my phone

https://farm9.staticflickr.com/8512/8357793223_b6ee178544_z_d.jpg

https://farm9.staticflickr.com/8214/8357793083_78fd0eb6f0_z_d.jpg

https://farm9.staticflickr.com/8500/8358854170_159f090573_z_d.jpg

https://farm9.staticflickr.com/8500/8358854278_18475b020d_z_d.jpg

https://farm9.staticflickr.com/8471/8358854108_0b63ff16da_z_d.jpg

And finally my favorite carb cleaner:


https://farm9.staticflickr.com/8354/8357793033_a57bc99c11_z_d.jpg
____________________
Former: Derbi GP1 50, Sachs XTC 125, Suzuki GSXR 400 GK73A, Kawasaki ZX7R, Suzuki DR250, Yamaha RD350
Current: 2011 Yamaha XT660Z Ténéré, 2003 Yamaha YZR-R1 5PW (In Build), 2009 Kawasaki ZZR1400

[HoggyF]

Just a tip
I wouldn't make an exhaust out of copper tube, the exhaust gases IIRC reacts with the copper and makes cyanide gas (not 100% sure its cyanide but I do know its something on the nasty side that you wouldn't want up yer hooter)

Otherwise keep up the good work

[Nope.]

[spikenipple]

Haven't you got it running yet?
____________________
C50 > GN250 > XJ600 > SV650S K7 > 2001 RSV Mille R > MT-09, XR400R > 2005 Fireblade (trackbike) + 2022 MT-09 + ZXR400 race bike

[Nope.]

[spikenipple]

Awesome sauce, glad to hear it and nice to see it's getting the treatment it needs!
____________________
C50 > GN250 > XJ600 > SV650S K7 > 2001 RSV Mille R > MT-09, XR400R > 2005 Fireblade (trackbike) + 2022 MT-09 + ZXR400 race bike

[c_dug]

Try these guys for your carb parts https://www.nrp-carbs.co.uk/

Used them a few years back when I was fixing up my TDR, very helpful guys and had all of the parts I needed in stock.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[c_dug]

XJ600 Diversion parts from them here
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[krarkol]

I love reading these threads about other people getting their hands dirty

My old suzuki gn125 had mikuni carbs and I spent a good hour with nothing but a philips trying to get the last screw out

With the copper pipe and carbon monoxide worry, I'm pretty sure the exhaust fumes are already carbon monoxide so it's not like the difference is going to be any worse
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Bandit 600 - deaded

[Stalk]