What have you done to your XS today?

Are you saying I shouldn't use either lower OR upper?
No... remove the old lower and use just the new seal. No seal needed on top... that's what the dust cover is for. Also, are you aware that the two outer races are different sizes? Did you install the correct ones, top and bottom?
 
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I`ve bought 2 All Balls kits last year and they came with this type of seal. Is that what you used? The base of the seal measures .03.
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Yes, that is the seal that I used underneath the new bearing on the stem. The stock rubber “seal” that I re-used doesn't fit against the actual machined part of the stem like the new one that came with the all balls kit, but at the base of the lower tree, so I didn't see an issue with putting it back. It shouldn't be getting in the way of anything. So if there was ANOTHER stock seal that should have been there, it must have been missing. And yes, I know I didn't mix up the bearing races; I kept them separate and installed them one at a time
 
Welll, after 2 surgeries this month I am back to the XS650. Still doing brakes, I can not get the MC to pump fluid???\
I have done every thing I can think of, compressed air from the top and bottom, tied the lever back for a day of so,,
nothing helps. I will take the MC off tomorrow and dismantle it. I hope I can find a kit for it??
Any suggestions??? I am running g out of ideas All I want to do is get the brakes working so I can sell it.

PM sent. Give me a call. Thanks.
 
Remove caliper from fork, remove pads. push piston back, usually by hand works if not use plier or c-clamp. Then the MC should pump it out, repeat a couple times. Just did a dual disk 4 piston per caliper brake this way. Easy peasy.
 
1980 XS650 Chopper Build

Painted and put back on the rear wheel and front end. Going to strip the tank for a bar metal look to match the handle bars and sissy bar. Not too stoked on how the tank came out my patience was limited on the tank. Installed a new set of pull back handle bars to the narrow front end. The bars make it extremely more comfortable.


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Got this On eBay for 30! Everything is in pretty good shape and is working, just wanted the MC housing but the whole thing works for me too! Everybody else wanted same price or more just for housing or for one that needs work, usually the housing is cracked and brittle from u.v. damage and age! Will be putting it on this weekend,it’s snowing here now but will be in high 50s this weekend, also put the tach on yesterday! My next project will be a center stand!
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Okay, I’m back at it again- this time with a proper bearing driver set, new bearings, and the old bearings to compare. I even bought a ruler. Now I am REALLY losing my mind! I measured the old bearing stacked on the dust cap. 38 mm. Then I measured the depth of the hole in the hub. 32 mm. HOW DID THE DUST CAP EVER FIT IN THERE FLUSH? This doesn't make any sense to me at all. What in the hell is going on?
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Okay, I just figured it out- maybe I learned something new that can help folks out in the future- the dust cap os actually two pieces- the inside is a solid spacer, while the little flare that actually serves as the dust cap is actually a sleeve that fits around the middle of it- driving it out I must have moved the cap further out than it was sitting. I tapped it back with a hammer and we’re good as new. That was an expensive lesson learned. At least now I have experience with setting wheel bearings and a brand new set of bearing drivers for the future.
 

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Okay, I’m back at it again- this time with a proper bearing driver set, new bearings, and the old bearings to compare. I even bought a ruler. Now I am REALLY losing my mind! I measured the old bearing stacked on the dust cap. 38 mm. Then I measured the depth of the hole in the hub. 32 mm. HOW DID THE DUST CAP EVER FIT IN THERE FLUSH? This doesn't make any sense to me at all. What in the hell is going on?

Truly, road followed by builder of old motorbike not an easy one, Grasshopper. Just read your latest two posts and I can fully relate to doubting your own sanity - been there a few times* and expect many others have too. Reading this thread, I was wondering where this was going . . . It's good that you have been able to reflect on this experience and learn from it. Onwards and upwards.

*Cam chain length - take a look here http://www.xs650.com/threads/miss-november-xs2-tribute.55057/page-15#post-604274
 
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Alright, mission accomplished. 50.00 and a week later, and I successfully seated new wheel bearings in the rear hub for the 2nd time, got the wheel back on the bike with the axle I bought off ebay after fudging my original axle threads. Also made use of my motion pro chain tool and riveted the chain instead of using the clip style master link. Took the top seal out of the stack and had room for both lock rings on the steering stem. Bike is nearly ready for spring. New rubber, balancing beads, completely rebuilt wheels and new chain/sprockets. Now I need to replace the cracked tach cable, check the sticky throttle cable, and probably rebuild or at least clean the carbs since they’ve been intermittently leaky last year.
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View attachment 160325 View attachment 160325 Alright, mission accomplished. 50.00 and a week later, and I successfully seated new wheel bearings in the rear hub for the 2nd time, got the wheel back on the bike with the axle I bought off ebay after fudging my original axle threads. Also made use of my motion pro chain tool and riveted the chain instead of using the clip style master link. Took the top seal out of the stack and had room for both lock rings on the steering stem. Bike is nearly ready for spring. New rubber, balancing beads, completely rebuilt wheels and new chain/sprockets. Now I need to replace the cracked tach cable, check the sticky throttle cable, and probably rebuild or at least clean the carbs since they’ve been intermittently leaky last year. View attachment 160324
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Looking good TZ! You’ve made yourself a great looking bike. As far as the bearings go....well it’s all a learning experience. On my XS2, I goofed up the bearing installation on Both wheels! :doh: But you live and learn and try not to make that mistake again. Keep up the good work buddy! :thumbsup:
 
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