What have you done to your XS today?

So I think my problem might actually be the gasket for the enricher body. I made a cork gasket that was thicker than the original and it started up just fine but it didn't last long. I know cork isn't good for carb stuff so I'll make another one from paper and give that a try.
 
Tiesco said:
So I think my problem might actually be the gasket for the enricher body. I made a cork gasket that was thicker than the original and it started up just fine but it didn't last long. I know cork isn't good for carb stuff so I'll make another one from paper and give that a try.
Click to expand...
Look through some of @Mailman old threads. Iirc... he had the same problem. Fuzzy memory.. but I think there's some casting flash there preventing a good seal.
 
Well my XS2 has been on the road for a little over a year now and the last time I had it out, I noticed the clutch lever pull was getting a little stiff, so today I pulled the left side cover and freed up the clutch cable and then , one end of the cable at a time, I pulled the cable out of the sheath as far as it would go and greased ‘er up.
D1D985C5-2BE0-4B1A-9959-416F4D059FFE.jpeg

Then I took the sidecover to the bench and pulled the worm gear apart and cleaned and greased all the components including the ball bearing inside. Here I’ve just reinstalled it. I’m also happy to see my cereal box gasket is still looking good! :D
62B17C17-6D70-4F64-905E-C5F1ACC9CA97.jpeg


Side cover reinstalled and the adjuster backed all the way off on the worm screw. Before I finalize the adjustments, I also clean and grease the clutch lever assembly, including the channel that the cable passes through, because when you pull the clutch lever that cable actually slides against and bends around the assembly.
3D7FF00D-3881-455F-AC70-8E2CD4273A24.jpeg
C7EC8934-921D-4921-9222-2C15C271CB2F.jpeg


When I got it all assembled I made my final adjustments at the worm assembly and the clutch lever. And gave it a little test, Much Better! I even put my little fish scale on it and it starts breaking at 8lbs, which is about as good as this one ever was.
I’ll take it! You know what I mean Vern?
CEDF0AE2-0F34-4BA6-84EB-BCBBB8F3195A.gif
 
20190906_174956-1.jpg
Got a New Sawzall Blade Today

But it was to modify/repair a swing arm before I put brass bushings in it.
20200503_153641.jpg
I had tried to install this on the "cafe" last summer only to find that whoever welded it up did not leave enough clearance for the chain.
Since the blue 77D is on the bench for a stock rebuild, I thought I would prepare a swing arm for a quick install when the time comes.
20200503_173934.jpg
After cutting off the brace, I ground down the left over welds, then cut a slot in the plastic bushings, out they popped.
Tomorrow I will install the brass bushings and an extra grease zerk as recommended by 5Twins.
 
Mailman said:
Well my XS2 has been on the road for a little over a year now and the last time I had it out, I noticed the clutch lever pull was getting a little stiff, so today I pulled the left side cover and freed up the clutch cable and then , one end of the cable at a time, I pulled the cable out of the sheath as far as it would go and greased ‘er up.
View attachment 165999
Then I took the sidecover to the bench and pulled the worm gear apart and cleaned and greased all the components including the ball bearing inside. Here I’ve just reinstalled it. I’m also happy to see my cereal box gasket is still looking good! :D
View attachment 166000

Side cover reinstalled and the adjuster backed all the way off on the worm screw. Before I finalize the adjustments, I also clean and grease the clutch lever assembly, including the channel that the cable passes through, because when you pull the clutch lever that cable actually slides against and bends around the assembly.
View attachment 166001 View attachment 166002

When I got it all assembled I made my final adjustments at the worm assembly and the clutch lever. And gave it a little test, Much Better! I even put my little fish scale on it and it starts breaking at 8lbs, which is about as good as this one ever was.
I’ll take it! You know what I mean Vern?
View attachment 166009
Click to expand...

Even the close-up pictures show very little grime or dirt. That thing is museum quality.
 
20200504_175619-1.jpg
Poor Man's Press
This is the first time I have held the swing arm in the vice while using threaded rod to install the bronze bushings. Why didn't I think of this sooner?
Also drilled and tapped for a grease zerk, all ready for a bit of black paint and it will be good to install.
 
I've been struggling to find gaskets for the carbs for some time now, trying to avoid mikes. Does anyone know where a guy can find the bowl gasket, choke body gasket, and valve seat assembly gasket for some BS38 carbs?

Thanks
 
Tiesco,

I have had real mixed results buying carburetor gaskets, I don’t like the tissue thin rubber gasket that goes under the choke assembly so I bought some gasket paper and I make my own.
I have also bought bowl gaskets that were sold as OEM Yamaha , but we’re not, they had to be trimmed to fit.
you can read about that and see some photos here.

http://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-22#post-546277

I’ve had some good luck buying parts from this place,

https://www.siriusconinc.com/m/search-result.php?make=2&model=XS650&part=&partno=&search=search

also EBay seller Niche Cycle Supply or NCS , stuff I’ve bought from them have generally been good quality.

The float needle assembly gasket, should be reusable, mine was aluminum. The entire assembly is still available , factory part from Partzilla. Sadly Boats.net no longer messes with old motorcycles.

Good luck on your search!
 
Mailman said:
Tiesco,

I have had real mixed results buying carburetor gaskets, I don’t like the tissue thin rubber gasket that goes under the choke assembly so I bought some gasket paper and I make my own.
I have also bought bowl gaskets that were sold as OEM Yamaha , but we’re not, they had to be trimmed to fit.
you can read about that and see some photos here.

http://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-22#post-546277

I’ve had some good luck buying parts from this place,

https://www.siriusconinc.com/m/search-result.php?make=2&model=XS650&part=&partno=&search=search

also EBay seller Niche Cycle Supply or NCS , stuff I’ve bought from them have generally been good quality.

The float needle assembly gasket, should be reusable, mine was aluminum. The entire assembly is still available , factory part from Partzilla. Sadly Boats.net no longer messes with old motorcycles.

Good luck on your search!
Click to expand...

Thanks a lot, Mailman. And my float needle gasket was a very thin paper gasket.
 
Superjet said:
JIS #2 makes a world of a difference in removing these little sons a gun! No phillips allowed lol
Click to expand...

I knew when i started that I should have the right tool but when I got one of them out without stripping it I said fuck it. I had to grind a Philips head to the right shape in order to get the others out. I have since ordered some Allen head replacements. I try to convert to Allen head as much as I can on this bike.
 
Last edited:

Similar threads

W
She runs! What’s next?
Replies
14
Views
417
Wrenchmorethanride
W
Mailman
The complexity of modern valve trains and maintenance costs
2
Replies
32
Views
1K
Paleomechanic
Paleomechanic
STARCROSSEDMOTO
77-81 XS650 "JADE" Tribute Build
2
Replies
33
Views
3K
Paj
Paj
Bountiful
Thanks for the warm welcome!
Replies
12
Views
2K
Grumpydog
Grumpydog
GLJ
XS2 Survivor resurection.
5 6 7
Replies
120
Views
11K
GLJ
GLJ
Back
Top