TCI system once again

I have the six friction plate set up. I am still shopping and doing some comparative pricing to help my bleeding wallet on this project. The metal plates are all in good shape and true, so they are going back in. Besides drilling them out, has anybody found a way to adapt the old JIS pressure plate screws to get enough bite for a re-install, maybe cut a slot for a big arse screwdriver.

The lithium grease debate has been a hot topic on a couple of vintage British bike forums for awhile now. Old time wrench spinners say they have doing it for years and swear by it. Others say it came over from the Ducati sites as a cure for grapping and noisey dry" Duc" clutch set ups. Those who have tried it to include myself, find it does work. My 1964 Trophy had bad clutch drag when going into 1st gear and you always had to kick a couple of times to free the plates, since applying the grease all of these symptoms disappeared and there was no slippage what so ever. During winter maintenance this year I will probably pull the plates and apply another coat since it has been well over a year since the initial application. Wet, dry, separate or integrated primary does not matter, the key is just a very thin coat, applied evenly on all of the friction plates, even after soaking in oil. All I can say it did work for me and I was a true skeptic on the whole process.
 
This came in today, I am on the fence about installing it since most of the electrical Gremlins have been eliminated. I have not put a meter on the battery when running but the lights definitely brighten when you spin the throttle. Everything is apart now waiting on clutch parts. I forgot I had ordered this harness back when I chasing spark, thinking it could be a broken or shorted wire I figured this would save a couple of steps. Anyway there is a 15 percent restocking fee and with cost of shipping it is probably not feasible to return it. I used one on the chopper I brought back to life, but there was a bare minimum of wiring. Thoughts anyone.......

http://www.tcbroschoppers.com/1980-84-yamaha-xs650-chopper-wiring-harness-6-pin-cdi.html
 
well, that depends on how much you paid for it..... shipping SHOULDN'T be too bad.... ( but you need to insure it too... and it all adds up
if you add up all the costs associated with sending it back and don't come out enough with enough money to go out and eat dinner with your sweetie ,.....what's the point ? you may at some date in the future need one.... depends on how likely you think you are to do a few more xs650's ! LOL
Good luck !
....
Bob.......
 
Knock $5 off it and advertise through the classifieds........or some other site where more of those guys hang out...........
 
Next problem, damned if I can completely identify the rear caliper to order parts for a rebuild. I can get close but not exact match.It is a Tokico and it has G1 on the rear. Can anyone nail it or point me to a site, Suzuki or otherwise for identification. It is opposed piston, breed screws on the top of each piston and the brake line feeds from the front. Photo's attached and always thanks for any help guys.......

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It definately needed new pads for sure!
 
Got it-1988-93 Suzuki GSX1100 Katana and other submodels FP and F. Parts on order and damn I am tired of looking at Japanese rear brake calipers......
 
Thought it would be a good idea to give you guys the final update on probably the world's ugliest motorcycle. Of course all fluids changed, (forks were fun since I had no idea what they are from, just played with the oil amount until it felt decent. (From what came out on the flush anything had to be an improvement.) New clutch plates and yes I did coat them with lithium grease, new cable, I even broke down and ordered the allen head screw set from Mike's. Carbs have been into twice so far and I am getting damn close, went up one level hotter on the plug and almost to point where I am happy. New brake pads all around, fabricated a new brake light switch with a universal job from Ebay. I thought I would pull out what little hair I had left out trying to get it set, then the front switch went out and I had to order a new one for a Suzuki since they are what the PO bolted on. With an illegal tag and staying on the back roads I have probably put about 50 miles on the machine since it came back to life. I will have to say, it runs exceptionally well, pulls strong, and shifts like butter. I had thought about keeping this one just because it has been such a PITA, but I think it will be hitting Craigslist soon since I have found a 64 Triumph Mountain Cub that is crying for attention. I still have to get some gauges mounted, wet sand a new coat of clear on the tank, JB Weld a cracked side cover, clean a little here and there, but it overall it is resurrected. I hope the new owner, (if the damn thing sells), does find a path for the bike. Cafe or desert racer, bolt on a hardtail, or just ride it to every Harley bike night around to prove "Beauty is truly in the eye of the beholder". Of course I am a realist and do know this one ugly arse motorcycle.......
 

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Good to see the progress made.

Could you post a pic of the gauge faces.

These sets are a one off in 74 i think. There is no reference to them in parts manuals but i have a set the same but they changed in during the 74 production run or for the 75B gauge set. If i am not mistaken the trip meter will be below the Speedometer meter. later 75 Speedometer gauge changed the trip meter to the top because the reset knob placement meant there had to be a conglomeration of gears for the reset to work.

Thanks
 
Very interesting and yes, the look is indeed....unique! But take heart Britman - you’ve got a genuine classic bike to ride with a snazzy looking double disk wheel and front end part.

...as long as you don’t....you know....<wait for it>.....get the “blues” while riding it.
 
:laugh: :thumbsup: and if I could find one that rolled it's eyes I'd click on that one too....
 
LOL Maxpete ! Now you just couldn't resist that could you ! LOL
if it were mine I'ed invest in a few cans of Krylon black paint and tone down some of or maybe ALL of that blue, but then it wouldn't be the same at all..... it is definitely unique and there is beauty in that by itself ! 50 miles and still chugging! not too bad for a summer project!
Well done !
.....
Bob.......
 
I've seen worse paint jobs. I've owned bikes with worse paint jobs. My Ol' '60 R-69 was painted a rattlecan orange and faded by the Nevada sun. Saddlebags were almost solid red reflective tape with curled edges. Ugly, but ran well.
 
Well she has clocks. Like everything else on the project, took a little of this and that and some rewiring to get the job done. I used the stock gauges from a 74-75 or somewhere around that era, and the aftermarket bracket for mounting. I had to lose all the cans to gain fitment, so I sanded the bare gauge bases with some fine paper for a brushed look and hit it some clear coat for a little protection, (just FYI I try not to ride in any rain.) I changed out all of the instrument lamp bases and converted them to the old style lighting. The only thing I lost was the turn flasher bulb. Since I am old as dirt I have an excuse to leave the damn things on anyway, usually on my way to dinner at 4pm in the afternoon. I think it gives somewhat of a Mad Max look, I just hope it doesn't distract from the pure beauty of the machine......
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