It's past time to start XS2 Resurrection

I've never had it hooked up. In fact the cable was removed before I bought the bike. I remember asking my brother why the cable was missing when I bought the bike from him. He said that the local Yamaha shop said it wasn't needed. The bikes started better without it. The E-start has always worked fine. I was going to ask you if you had tried yours without it.
A while back I went through the starter drivetrain gearing... part number by part number. They match for all years including the XS2. My 80 SG starter and drivetrain is identical to yours. They should work just fine without the decompressor.... they do on the rest of 'em. ;)
 
Had the decompresser working on a 73 no issues on that one.
I think they are cool in a steampunk or maybe rube goldberg kind of way.

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Used to have that problem with old Brit bikes, once I got them cleaned up I'd spray them with clear and the rust would be held at bay for a while. Good till the next tire change anyway.
It’s really surprising how much better you can make rusted rims look. Much of that rust is just laying on top of the chrome. You get it all cleaned up and it’s just small spots.
You can make them very presentable.
 
Declaring Phase 1 complete. :woowoo:Phase 1 was to get the bike back into a run-able and dependable state. I think it is. Changed oil in it and the oil that came out looked good, no metal flakes or bits of plastic. Motor has 200 or so smiles on it and runs fine. No major work needs to be addressed, minor job changing the 38 tooth rear sprocket back to 34 teeth.
Phase 2
Time for Phase 2, get the original engine rebuilt, back in and running. After posting a picture of someone referred to it as a lump. That's a good description. Decided to spend some time today getting the cases a bit cleaner. Not trying for perfect, just clean enough to take apart. What I started with.
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After a bit of cleaning it's clean enough to take apart. Didn't do anything to the cylinder or head.
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Was surprised when I looked at the sump filter. It look great. No tears, no metal and no plastic.
 
Oooh an engine to rebuild! I might have some green gaskets I could send you! :laugh2:

Glad to hear your oil change looked so good! It’s funny , when I did my first oil change, I removed the bolts from my sump filter and grabbed the sump plate with my hand and tried to see if by any chance it would just come off.
It wouldn’t, so I got up to go get a small block of wood and a rubber mallet to persuade it and right then it went PLUNK! And just fell off in to my drain pan! :)

Hope this rebuild goes smooth with no surprises for you. :thumbsup:
 
I might have some green gaskets I could send you! :laugh2:
No way Josey. Awhile back I bought some XS1 gasket sets. They have black gaskets. No 4 hole gasket though, the Athena set I bought had a black 4 hole gasket, rest were aftermarket Green.:poke: Head gasket is different than mine. Anyone need a couple of XS1 head gaskets let me know. Going to use black gaskets on this engine so it looks right.
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Aux. fuel tank...off a Honda lawnmower I got off Amazon along with the on/off petcock. I think I paid less than $25. I have to bring the wooden sides in sometime so if fits the cam cover.

Well, it certainly gets around the perennial corrosion issues but it does lack a certain something in the “style” department....:laugh2:
 
Got the engine knocked down. One minor surprise. The front cam chain guide still had most of the rubber on it, except it was broke in half. Not sure when or how.
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Going to take engine cases to get welded next week. Not sure how well crack shows up in the pics. After cases are welded start ordering parts.
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That’s crazy! I’ve never seen a cam chain guide snap in two like that. Regarding the cracks in your case , I can imagine the broken frame was putting a lot of stress on the cases. Well.....you know, that and the eighteen year old hell raiser twisting the throttle! :D
 
That’s crazy! I’ve never seen a cam chain guide snap in two like that. Regarding the cracks in your case , I can imagine the broken frame was putting a lot of stress on the cases. Well.....you know, that and the eighteen year old hell raiser twisting the throttle! :D
Crack was in the case when I bought the bike. Used to clean it off with carb/break cleaner and then put 2 part epoxy on it to stop oil leak. That would last for a month or 2. Not sure when frame got broke. I may or may not have had something to do with that.:sneaky:
 
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