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  1. rbirkey

    1981 Yamaha XS650 - Project Bike #6

    That would explain it - thanks! I'll see if I can bend them back!
  2. rbirkey

    1981 Yamaha XS650 - Project Bike #6

    I'm losing my mind. I can't figure out why the OEM headlight brackets that I removed from this xs650 don't seem to fit either the original headlight bucket I removed or the new chrome one I have ready to install. The brackets appear to be approx. 6" apart when oriented straight forward. The...
  3. rbirkey

    1981 Yamaha XS650 - Project Bike #6

    After rebuilding 2 previous XS650s (a 1977 and a 1981), I'm back with my third project. This is another 1981 that a friend of mine purchased from a buddy who bought an old house in Madison, WI to flip, and this bike was in the garage under a pile of junk. From the license plate, it appears to...
  4. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    I was able to finish the headlight and new instrument wiring today. I took it for a short shakedown spin. Need to address a few more items: Front brakes are still mushy - more bleeding? Left front signal stopped working Clutch needs adjustment, grabs too quickly Check front fork oil -...
  5. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    The smoke you see coming from the exhaust was the burnoff of oil we squirted in the spark plug holes before we started 'er up! It has since cleared up. I am truly amazed at how well this bike runs right off the bat! I was not expecting that. Today, I plan to complete the front bucket and...
  6. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Well, a significant milestone was reached tonight. The XS650S project bike runs for the first time since 2002! I applied a little choke (first click) and it started right up. Then I adjusted the idle screw and it ran like this! My friend Harrison is very happy, because he's buying this bike!
  7. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    OK, I *think* I have discovered the main front brake problem. When I rebuilt the master cylinder, I put the spring and rubber end cap in the wrong way (inexperience). Now that I have corrected that, I seem to be generating some hydraulic pressure, and I will continue bleeding all the air out of...
  8. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Well, I've tried everything I know to get brake fluid into the front dual brake setup, with no joy. First I filled the calipers, then the two brake hoses from the junction to the calipers, then the hose from the master cylinder to the junction. There is fluid in the master cylinder covering the...
  9. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Rechecked the caliper seal ring and slot and it is clean and in good shape. Now I am trying to put everything back together from the bottom up and filling each section with brake fluid as much as I can as I go. Hopefully that will be enough to start getting some pressure so I can bleed it.
  10. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Hey all, I have rebuilt the stock master cylinder and it feels like it is working as it should. I have installed all new front brake lines and am now trying to fill the new front system with brake fluid and bleed the air. So far, I've spent several hours trying to get the air out and get the...
  11. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    In speaking further with MikesXS I decided to order their 1MH Front Master Cyl. (16mm. bore) - Part 08-0265
  12. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    So, I decided to rebuild the front brake master cylinder while I had everything apart and adding the second front disc. I ordered the 08-0204 kit from MikesXS thinking is was the right one for dual discs - but when I took my master apart, it seems I have the single disc master cylinder (Duh!)...
  13. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Thanks - I guess this must be it... it threw me off because it is square and didn't look like the one I replaced on the 1977 Yamaha XS650D. So will the 2 prong unit work with the three prong receptacle, or do I need to get a different unit? Randy
  14. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Hello Everyone, I hope you are all doing well during these weird times. I am doing fine, but have been busy on some other projects. But, I am back working on this project and hoping to get the 81 Yamaha XS650S running in the next week or so as I have a buyer for it! I am currently working on...
  15. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    OK, thanks. I've placed my order from Partzilla and hopefully, they will be the right ones! Anybody have a suggestion on where I can find a brake hose bracket for the left side front fork/fender, now that I'm adding the European left front brake assembly?
  16. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    So, I found these exhaust rings sort of stuck in my heads... removed them and cleaned them up. They look pretty good to me... but what do I know? Should I go with just the new copper exhaust seals, or the old ones... or both? What do y'all recommend based on your vast experience??
  17. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Well, I ended up having to send the MAC Performance TT exhaust system back because I could not make it fit my bike and frame. There were no instructions, diagrams or any help from the manufacturer. Niche Cycles was good enough to give me a full order refund but I lost about $50 on shipping. Bad...
  18. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    MAC may have changed flange and attachment design a bit. Here is how this TT kit looks at the head. It all seems to fit fine on this end Its the muffler end that doesn't fit.
  19. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    Yeah Bob, I was really surprised at the unexpected poor customer service I received. I still can't believe that MAC Performance can remain in business treating customers this way. Hopefully, it was just a fluke. Just to clarify, the headers fit OK at the head flange. However, even with them...
  20. rbirkey

    1981 Yamaha XS650S - Project Bike #5

    It's been a while since I have posted in this thread. My carbs are back together and ready to be mounted. I am still wrestling with what do do about a seat and whether to chop the frame a bit to allow for a more traditional, flatter seat position. The biggest issue has been the exhaust system...
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