Marc
Member
Registered: 11th Aug 02
Location: York
User status: Offline
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There is a common mod that XJR owner's do to their bike's. This involve's taking out the tip's of the back boxe's and replacing them for larger bored less restrictive item's.
What it kind of looked like before:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike8.jpg
Inside you can see how restrictive they are and how exhaust gases come out of several port's:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike9.jpg
Minus the exhaust tip:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike10.jpg
The tip cut out ready to be removed:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike12.jpg
Another shot inside:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike13.jpg
Old tip next to new tip and end cap:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike14.jpg
These were fabricated by my brother.
Finished exhaust with new tip and end cap:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike15.jpg
Next was the air box mod, again this was fairly restricted so was modified to make it less so. Originally a K&N was to be used but in the end an Astra 1.4 filter was bought from Halford's and butchered!!!!!
How it originally looked with a fairly small opening:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike1.jpg
This had been cut prior to the pic, hence the paper!
The air box opening was then made as big as it would go to allow as much air as possible:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike2.jpg
The air feed that originally went in to the air box:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike3.jpg
And how it was when in the air box:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike4.jpg
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike5.jpg
The modified air box and the air feed, now minus the plastic pipe which was removed after the opening was made bigger to allow more air flow:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike6.jpg
Finished air box and air feed:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike7.jpg
Airbox back in the bike:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike16.jpg
Now the problem! As the exhaust's were now less restrictive the bike pulled better, but also the air box was getting more air flow which resulted in the bike losing torque!
The opening of the air box was restricted again so that air flow wasn't as free. A piece of wood was cut to shape and screwed over. Air flow now come's from underneigth:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike17.jpg
Obviously this is only temporary and an alloy cover plate is being made!
Next, the rocker cover's and forks were stripped of their laquer, this was because corrosion had set in. The laquer was removed with nitromor's, wire wool was used in between each application:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike18.jpg
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike19.jpg
Nitromor's was also used on the wheel's. They had previously been spun in a lathe to give them a polished rim. They were never laquered so started to corrode. They were placed in a vice, held in place by the spindle whilst rubbed down with nitromor's and a drill attachment, not wire wool this time but a polishing wheel.
All part's then gained a coating of Autosol and were buffed up using the polishing wheel. This will give better protection than the laquer, but further application's will need to be applied in order to stop them coroding in the future.
Exhaust's back on the bike:
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike20.jpg
http://img.photobucket.com/albums/v30/16vmarc/Yamaha/bike21.jpg
Plug's were also changed for Iridium's and the cam shaft clearence's were checked. Possibly in the future the bike may be treated to individual K&N filter's for the 4 carburetors.
The bike in question:
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good read 
