"Smurfette" - Slow build and Q&A thread

Do some research before buying a rear guide. From what I have read they rarely go bad. Also check with MMM over at 650central.com for some price comparisons. Oh yeah, the "bottom gasket" is typically referred to a cylinder base gasket. Good luck with your rebuild, and don't forget a cam chain breaker/riveter if you don't already have one.
 
CoconutPete said:
Front cam chain guide (?)
Click to expand...

Pete, I just finished my top end rebuild. Was fortunate that my OEM parts guru was able to track down an OEM front guide for me in the Yamaha system somewhere.

In case he hadn't been able to I had bought one from XS650Direct. (Canada's MikesXS).

When I compared the two, I discovered the bolt holes in the Mikes guide were drilled at a bad angle and weren`t very cleanly threaded. However in saying that, prior to installing my new OEM guide, I did a test install on the Mikes and took some measurements of where both guides sat. There was only about a 1mm difference in positioning in a couple of places. I think you would be OK with a Mikes front guide and I would use this one. FWIW. YMMV.
 
willis said:
Oh yeah, the "bottom gasket" is typically referred to a cylinder base gasket.
Click to expand...

Thanks!
Last time I rebuilt a motor I was a little punk in Denmark and I ordered all the parts in Danish. Typing those words into the search box here strangely returns nothing!


Updated parts list:
Copper washers to replace the rubber covered ones on cylinder head (Mikes)
Sealing Washer Kit - Bottom End (Mikes) (why is it called bottom end if it's for the oil delivery tube etc.?)
Spark Plugs (wherever)
Gasket kit (Mikes or eBay)
Front cam chain guide (Will check condition of current OEM one)
Rear cam chain guide (Check OEM / Mikes)
Cam chain (mikes or eBay)
Cam Chain Breaker/ Riveter
Cam chain master link (mikes or eBay)
Possibly Piston rings (Partzilla, formerly boat.net?)
 
The cam chain comes with the link...I was fooled to buy a seperate one thinking there was none with the chain. Guess I have a spare now.
 
Superjet said:
The cam chain comes with the link...I was fooled to buy a seperate one thinking there was none with the chain. Guess I have a spare now.
Click to expand...
Yeah... Boats.net got an extra 5 bucks from me too....:rolleyes:
 
Might as well do the valve guide seals while you are in there too and check if the valves need lapped. In my opinion since you are already in there you might as well do it.
 
Pete, read through your shopping list. Here is a link to a post by 5twins in my thread where he gave me sources for a lot of the stuff needed.

http://www.xs650.com/threads/on-the-road-again-at-40-the-bike-that-is.49360/page-11#post-515260

Cam chain is still available from Boats.net or you could get it through Partzilla.
Cam chain breaker/riveter is still available.
Valve spring compressor is out of stock from that supplier, but others are available in eBay.
Gasket kit and valve seals still available.

Valve lapping compound: http://www.cylinderheadsupply.com/clovercompound1.html

Valve lapping tools: https://www.amazon.ca/gp/product/B004GBJAOG/ref=oh_aui_detailpage_o07_s00?ie=UTF8&psc=1
 
When I did my valves, i tried a cheapo spring compressor from HF with no luck. I ended up going to Auto Zone where they do tool loans and got an automotive style. I think I actually had to pay for it on my credit card, but was fully refunded when I returned it like 3 hours later.
 
Yep. I went and got a compression tester from Auto Zone and returned it a few days later. They basically just charge you to buy it and refund you.

I had read in several places that the HF ones were horribly inaccurate so that's why I went and borrowed one. This engine has a lot of unknowns compared to my other XS. For instance.... the bike didn't have an odometer on it when I bought it, so mileage is unknown, so I may have considered the top end job even without the 60PSI reading on the right.
 
Got the hoop welded on this weekend.
Brackets for rear fender and seat are next.
Then the steering stop.

I’m trying to do all the mocking up, welding etc. before I tear her down and yank the top end apart.
 

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Well... what do you all think?

Weld on top of the side or heat it and bang it with a hammer?

Let me know if the picture doesn't clearly show the problem.
 

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bent lower triple? Option #3: heat and use a fork tube for leverage to bend back to straight?
 
Actually that pic does make the lower triple look a little whacky - it looks fine in person.

The problem is the steering stop. It's bent. I assume from the bike being dropped and the handlebars crashing the opposite "stops" into each other.

One side has about 1/4" - maybe a little more clearance.
On the other side, the top triple hits the tank.

The way I see it, I can use a welder to just build up material on one side and grind it flat.

Or.

Try to straighten the whole thing out somehow.

Welding seems easier.....
 

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Seems like your option, either would work. would probly try a thick metal bar low against the side of the stop and a smack it with a sledge hammer. A friend to brace against frame for the strike.
Get that lower triple on a flat plate. If the tab's bent odds are..........
 
Good point about the possible bent lower triple.....

Remove it, remove all hardware and just sit it down on something I know is flat, like a kitchen counter. Is it as simple as that? It seems like it would be, just making sure here.

I'll probably try the welding approach tomorrow afternoon. I gotta pull the forks apart. Not looking forward to that. They are going to stink so bad based on prior experience....
 
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