1981 Yamaha Maxim 650

[Boost4VR4]

So I got a bug in me to look at motorcycles, so I perused around on Craigslist in my area. I found a very clean bike for the year at a really cheap price. Cheap as in, 100 dollars. Came with full windscreen, back storage box, and of course all of the engine and transmission.

I have already started to tear into it and found the engine is seized up. There was water in half of the engine and no oil in the crankcase. The engine will need a rebuild. The trick to this project is finding the parts for it. Thankfully, most of the parts I need I can get, there are a some that will need to be aftermarket.

I don't have any pictures yet, however, stay tuned.

PS. I am working on the Stealth as well.

[j2k4]

PS. I am working on the Stealth as well.

Oh, sure....:p

[Boost4VR4]

Made a lot of progress on the bike already. It will probably be running in a few weeks.

http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_1.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_2.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_2.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_3.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_3.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_5.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_5.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_4.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_4.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_6.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_6.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_7.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_7.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_9.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_9.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_8.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_8.jpg.html)

[Boost4VR4]

http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_11.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_11.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_10.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_10.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_13.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_13.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_12.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_12.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_15.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_15.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_14.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_14.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_16.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_16.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_18.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_18.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_17.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_17.jpg.html)

[Boost4VR4]

A little polishing today:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_20.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_20.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_21.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_21.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_22.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_22.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_23.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_23.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_24.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_24.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_26.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_26.jpg.html)
Carburetors cleaned out, bottom left carb jet needs to be replaced:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_25.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_25.jpg.html)

[Boost4VR4]

Ah more work completed this weekend. Motor came out last weekend and this weekend, motor got disassembled:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_27.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_27.jpg.html)
The shrapnel is the cylinder wall/sleeve for cylinder 3, remember that mangled piston?
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_28.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_28.jpg.html)
There were pieces everywhere.
So I opened it up:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_29.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_29.jpg.html)
Cleaned out all of the pieces and checked the transmission gears. The gears were unscathed!
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_30.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_30.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_31.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_31.jpg.html)
Bad pistons and connecting rods
New pistons and connecting rods installed:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_33.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_32.jpg.html)
Shot of the top half of the engine:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_34.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_34.jpg.html)
THe following is coming for the bike:
Caliper rebuild kit
Brake Master Cylinder rebuild kit
Full Engine gasket set from Japan
Carb float needle
Carb float bowl gaskets
Oil Filter
Spark plug set
That's all I have for now!

[j2k4]

I hated working on bikes - glad to be able to watch you do it, Kev. :p

[Boost4VR4]

Well, I picked up the Engine Gasket set that came from Japan. Can't believe it took only a few days to arrive. So this weekend I will build most of the engine. I need to get the cylinder and head hot tanked, valves lapped and cleaned up.

[MDoe8]

man that engine was nasty!

[Boost4VR4]

Machine shop has head, cylinder, and cams, waiting for all of that, haven't started putting it together, so will be doing that this week. Been trying to get other stuff finished up at the house.

[R/T93]

Good update, you will be so happy when it runs

[Boost4VR4]

Rebuilt the carburetors, got a set of pod filters to go on the carburetors. I had to align the carburetors. Here's what they look like now:
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_3_1.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_3_1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_2_1.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_2_1.jpg.html)
http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/temporary_38.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/temporary_38.jpg.html)

[Boost4VR4]

Machine shop says head and cylinder are done, so waiting until next week to pick up, the budget isn't there currently. I will probably start assembly of the case and everything this weekend.

[DocWalt]

Good progress so far Kev. You gotta get this motivation back for the Stealth ;)

[Boost4VR4]

I haven't had an opportunity to get the stuff back from the machine shop. I am going to be delayed even more now that I am pursuing a lawsuit.

[Street_Chally73]

Very nice resurrection so far! Bikes & quads are fun and easy to fix up, aren't they? ;)

[Boost4VR4]

Getting close to finishing this bike. I am just about done with the engine. I have been polishing the crankcase housings which has been really tedious, but the bike is getting restored to its former glory.

[Boost4VR4]

Very nice resurrection so far! Bikes & quads are fun and easy to fix up, aren't they? ;)
Yea these bikes are much easier and cheaper than any car.

So for some progress, I ordered the mirror replacements, handlebar grips, and a riding jacket. I have been wearing the jacket to break it in as it is stiff still. It wasn't a cheap jacket, but I got it cheap.

[Boost4VR4]

Ordered fuse block and got the mirrors and fuse block. Will be working on installation this weekend. Will also be cleaning up fairings, windshield, fixing brake caliper, and doing other odds and ends on the bike.

[Boomer3000]

Nice, I didn't tear quite as far into mine as you have. I also didn't take many pictures till after the fact :(

[Boost4VR4]

Well, tax returns are coming in higher than expected, so I will be able to get the parts from the machine shop back soon. Meanwhile, I got on to working on the bike even more. I cleaned up the windshield quite a bit, I started looking at the wiring, fixed the caliper issue but still figuring out if the caliper needs to be replaced or if I can still use this caliper. I am having problems holding pressure in the caliper, so I am suspecting something internal isn't working properly, or the master cylinder needs to be replaced. I will probably end up replacing both just for sanity sake, even though I rebuilt the master cylinder already. I am working on the luggage box. Once I get the 2 things back from the machine shop, this project should wrap up fairly quickly.

[Boost4VR4]

Got the rest of the engine back, now it's on to assembly. Working on the wiring and building the engine. Will start posting progress.

[Boost4VR4]

Well, new snafu, engine gasket kit is incorrect. The 1974-1981 Maxims are different from the 82-83 gasket set I purchased. I found a replacement gasket kit so I will probably put it up on ebay when I get the right gasket set.

[Boost4VR4]

I have been popping in working on the bike lately. I removed the luggage box and started fixing the luggage box. There were some damages and some bondo required to patch sections.

I finished polishing all of the chrome, steel, and aluminum on the bike. There was a few different bars that needed to be polished up nice and the luggage rack bars were looking shabby.

Other than that, nothing new.

[DocWalt]

Get to work then :)

[Boomer3000]

pics or it didn't happen.

[Boost4VR4]

Polished foot peg brackets, did some various wiring cleanups. Will post pics soon. A decent amount of work has been done. I will be installing the windjammer on the bike and testing out the wiring through the windjammer.

[Boost4VR4]

Got the windjammer installed, wiring is solved for the bike, just need to put order in for all the rest of the parts. I am on hold though as the wife is having some health issues that need to be taken care of first. So more to come.

[Boost4VR4]

http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/e9dd8e26-f21c-4fee-a1d0-45bef7a1275d.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/e9dd8e26-f21c-4fee-a1d0-45bef7a1275d.jpg.html)

This is where I am at today.

[Boost4VR4]

http://i869.photobucket.com/albums/ab253/kevpi1/1981%20Yamaha%20Maxim%20650/WP_20160624_14_06_45_Pro.jpg (http://s869.photobucket.com/user/kevpi1/media/1981%20Yamaha%20Maxim%20650/WP_20160624_14_06_45_Pro.jpg.html)

[Boost4VR4]

No new work done on the bike due to bigger commitments with our home. I never got my order in, however, I think my solution for the gaskets issue is to make my own gaskets. If I do it this way, I can save money and learn something new. I may do this for the exterior covers and possible the engine casing, but internal gaskets, just buy them one-off.

[DocWalt]

Making gaskets is a useful skill to have! I'd highly recommend a set of gasket punches so you can make the holes for fasteners and such, but the rest can be done free hand.

[Boost4VR4]

It's been a while since I have posted, but now things are getting more stabilized and I can work on this project again.

I picked up some fiber/rubber gasket material from NAPA. It's only 8.59 a roll and the roll is 2 foot long by 1 foot, so not too bad. I started making some gaskets last night and will continue to make some tonight. I had started making some gaskets already prior to this, mostly RTV gaskets, but some of the gaskets need to be the fiber/rubber material. Will post some pics soon.