The 1982 Yamaha XJ 650 is considered a classic motorcycle. Restoring one can be both rewarding and educational, but will take time. Depending on the condition your bike is in, you may want to set aside a couple of months to restore the bike. With the right tools and equipment, almost anyone can complete a Yamaha XJ 650 restoration, given they have the patience to follow through on the project. Be assured, the final product will be well worth the work and time.
- Skill level:
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Things you need
- Complete set of automotive tools
- Engine Hoist
- Plastic bags
Purchase the owners manual. This is available from either the manufacturer or from a variety of online sources. The owners manual is an essential part in restoring the 1982 Yamaha XJ 650, as it will outline every part of the motorcycle and give detailed instructions on how to disassemble and reassemble it.
Strip the bike down to the frame. Inspect each part of the bike for rust, chipped paint and any missing or broken pieces. Purchase all missing and broken parts online.
Remove the engine from the bike frame. Use an engine hoist to remove it. The engine is small enough to remove by hand if two people do it, but it is both easier and safer to use an engine hoist if you have access to one. Clean the engine with a small brush. Cover all electrical parts, the air intake and carburettor with plastic bags and seal with rubber bands. Now wash the engine with warm water. Make sure no water enters the vulnerable areas.
Paint the individual parts of the bike in its original colour. You can purchase the paint from a local garage, the manufacturer or online. You can also hire professionals to paint the motorcycle for you if you do not have prior experience doing this.
Reassemble the bike. Consult the owners manual constantly to make sure you are assembling it correctly. Begin the assembly by reinstalling the engine. Once you have properly reinstalled it move on to rebuilding the frame.
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