78E Standard Revival

member28833 · Dec 31, 2020

Runnin low on garage time this weekend, I did more midnite motorcycle assembly last nite. The throttle/mc side.
If you look closer you can see all sorts of the original wire wraps, rubber weather boots, etc.. I put a lot of time into the little details and positioning, cleaning, lubing, of the controls, wire routing, etc.. Anyway, these are the SR500 handlebars which are just a smidge sportier than XS Standard bars.
:cool:

Its New Years 2021 eve, the 78E is on track this year. Have a Happy New Years eve!

fredintoon · Dec 31, 2020

Machine said:
https://www.ebay.com/itm/324017978732
Considering this DID 530 × 120 chain for the cheap price, DID brand. And I think it is a light in weight chain?
Opinions?

Hi Machine,
yeah, DID makes good quality chain.
FYI all makes of #530 chain are dimensionally identical to #50 agricultural chain and run on the same sprockets.
Motorcycle chain lasts longer than agricultural chain because it's built from better materials.
I run #530 O-ring chain which has bigger side plates, Alas you hafta remove the inner chain guard to run it and are limited
to a 17T front sprocket because an 18T is too big for the chain's side plates to clear the shifter shaft..
An O-ring chain's self-lube gives it 2x the life of normal chain and 5X the life if you run a Scottoiler or other automatic chain oiler.

member28833 · Dec 31, 2020

fredintoon said:
I run #530 O-ring chain which has bigger side plates, Alas you hafta remove the inner chain guard to run it

Hi fredintoon, I have the DID 530 O-ring chain on my other XS. It looks so tough and is perhaps a bit heavy.
The 78E has to compete with the sportier 79 SPII on performance lol.
Both are geared with 17f & 32r, both to be Tuned exactly the same. Im hoping this DID Standard chain is just light enough to give a roll on advantage

fredintoon · Dec 31, 2020

Machine said:
Hi fredintoon, I have the DID 530 O-ring chain on my other XS. It looks so tough and is perhaps a bit heavy.
The 78E has to compete with the sportier 79 SPII on performance lol.
Both are geared with 17f & 32r, both to be Tuned exactly the same. Im hoping this DID Standard chain is just light enough to give a roll on advantage
View attachment 181761

Hi Machine,
like the aircraft designer's motto:- "simplificate and add lightness"
I'd suppose that a good way to "add lightness" to an XS650 would be to reduce it's rider's food intake?

member28833 · Dec 31, 2020

fredintoon said:
I'd suppose that a good way to "add lightness" to an XS650 would be to reduce it's rider's food intake?

Good point. So how am I going to keep up with my 110lb gal on the sportier XS bike then?
Oh wait, just remembered that she only wants to ride back seat on the 78E.
:cool:

Here is how it sits 2021 waiting, chain, chain guard, single outlet breather, wiring bits.. etc..

member28833 · Jan 6, 2021

Barely an update :lmao:

Still waiting for the DID chain for fitment and torqueing of components. (Ebay delivery slower lately?)
Did realize just how intrusive a stock horn looks hanging over an otherwise eye pleasing XS650 engine. Gone! as in the previous XS's.
Still needing just a few gizmos such as a "Special" chrome chain guard. It use to be very easy to find such items locally with just a few phone calls.
Pics-
Breather, carbs, etc. all on the "to do" list.
96 Ford F150 lost the rear main seal, oiled the clutch. Takin up XS time...

member28833 · Jan 7, 2021

Late this eve, I found the DID 50 chain on my porch, FedEx dropped ahead of delivery

A quick check on fitment confirmed that with the 350mm length Triumph shocks combined with the 32 tooth rear sprocket, the chain does adequately clear the swingarm pivot seal. It is close enough to expect that seal to take a little more beating than a stock XS set up, but its a go.
Looking forward now to the Dremel grind chain to length and get on with buttoning up the engine left side.

David Toll · Jan 8, 2021

Hello Randy,
Member, AndersJ posted "Special" items for sale in August in the classifieds. He had a special chrome change guard for sale for $5. Might be worth a look.

member28833 · Jan 15, 2021

Happy Friday ! Ya, its been over a week lol.
On the chain length I used the measure Three times, cut Twice method. Lol.. With 17f & 32r sprocket gearing I wanted to experiment and see just where the axle position would end up with a 106 link chain length. Answer, Too far back in the adjustment range to even consider. So, a 104 link chain length is once again confirmed as the best. And with the 32 tooth sprocket, that puts is more than half way rear in the range. Perfect "for now"

Next up was to confirm the front sprocket was "good n tight" using one of my favorite special XS tools, the 36mm 1/2 drive 6 point socket along with my ancient beam type Craftsman torque wrench. (Long Lever). I did this nut years ago in Sandy Oregon so I figured it best to check it.. Why? Cuz. But it of course was tight.

Now onto the Rotor / Stator. Here is a cool twist. Remember that 79F 2 years back? Cleanest and best testing Rotor/Stator combo ever seen. Yup, hoarded for this 78E.
So I scuffed the contact rings and painted the timing mark on the rotor because my eyes aren't getting any younger... now where the heck did I stash the key?

Anyway, that's XS progress amongst a still very busy 2021 so far. Gotta go to town but expecting more XS time this evening..
Cheers, -R

member28833 · Jan 15, 2021

Lifted the bike a tad for less bending over. (After changing the oil in the Mazda MX5 lowlow)
Favorite kind of master link clip snapped exact! Front chain guide all snug and bent just right. Clutch rod clean, seal greased.
Rotor, So clean. Seal wiped clean and Rotor torqued on.
Stator is more ready than I am at the moment.

short break needed here :umm:

Mailman · Jan 15, 2021

Looking very nice there Randy! :thumbsup:

member28833 · Jan 15, 2021

Darnit, I got myself stuck temporarily. See if you clip that new master link chain together, Before routing the Stator wire harness through the chain guide, well you must back track.
So I just organized left side engine cover parts for next time avaliable.
Racin' the Gorge 220 tomorrow am.
Eastern WA Winds !
New Airfilter, 05-20wt Synthetic, Full Premium
:cool:

member28833 · Jan 16, 2021

Two clutch choices to make before that left cover goes on.
I can choose the newer clutch actuator which has the cable anchor in a different location from the pivot? (Nearer) Or use the original 78?
And I could trade the clutch rod to a one piece aluminum rod. On the fence there about the engine temperature expansion issue some have mentioned. Or use the original 78?

5twins · Jan 16, 2021

While you have that cover off and no worm mounted, you may want to check it for a small "defect" found on many, if not most of them, and remedy it if found. You often find a small raised casting ridge around the hole that the worm mounts into .....

This can hold the worm mounting tabs away from the cover and if you tighten the mounting screws much past snug, the tabs get pulled down and distort the nylon worm. This can cause worm binding. A few minutes with some small Roloc discs will take care of it .....

bosco659 · Jan 16, 2021

Don’t use them often but those small Roloc discs are great. I recall years ago I had a snowblower engine that blew a rod through the crankcase. Had it welded and the Roloc discs made short work of removing the excess weld and made the repair nearly invisible.

bosco659 · Jan 16, 2021

Machine said:
View attachment 182830
Two clutch choices to make before that left cover goes on.
I can choose the newer clutch actuator which has the cable anchor in a different location from the pivot? (Nearer) Or use the original 78?
And I could trade the clutch rod to a one piece aluminum rod. On the fence there about the engine temperature expansion issue some have mentioned. Or use the original 78?
View attachment 182831

Bike is looking great!

member28833 · Jan 19, 2021

Back to routing the Stator harness behind the front chain guide.
Altered and Strengthened the chain guide itself with Vice grips.
Spaced the rear mount lower with one thick washer, flange nut underneath. Turned out very sturdy too.

Finally that fresh DID back on.
Clutch rod decision of Stock vs aluminum One piece came down to leave it stock for now.
Actuator decision next up..Thats a wrap for Monday.
-R :cool:

member28833 · Jan 19, 2021

5twins did mention that actuator hole casting blemish? And yes, this did need to be addressed. I just carved the seen lip off with some modified deburring tools on hand.

This 79 side cover is in very original shape. It does match the "original patina" look the rest of the engine has too. It's a "no need to polish" look lol..
I'm going to start with the 82 clutch actuator which has the potential for a slightly longer clutch rod throw while having ample free play up on the lever pivot adjuster.
Fingers crossed this is a good combo with the 78E clutch.
-R

Mailman · Jan 19, 2021

Machine said:
"original patina"

Patina? What’s that?

member28833 · Jan 19, 2021

"Patina" in Irish terms is like..
"its as shiny as me ol tooth"
Figured that other excuse to not polish might get noticed by Mailman Bob lol

Good luck tho, I have a spare cover which is a great candidate for polishin. Whats your address?

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