1976 XS650C Restore

[cycleranger]

So I picked this up almost four years ago and it's been sitting in the shop waiting it's turn.
Today its turn came up!

A two-owner bike with about 40K on it that hadn't been ridden in ~14 years.
(And very little before that since the 80's.)
The PO was an engineer and kept through records of every thing he ever did to the bike and when. It also came with a box of spares from a '75 his brother had torn down. Tank, tins, fenders, and misc. stuff
Here's how looked when I got it.

 

[cycleranger]

Today I started tearing it down. The rubber battery box melted while it was in storage.

Anyway, I've restored several Hondas but this will be the first Yamaha I've worked on since high school.
I can already tell it's going to be fun, the Yamaha shop/parts manuals kinda suck (imho) compared to the Honda ones.

I'll post more photos as it goes along, I'm sure I'll have questions and need some advice from ya'll.

 

[racerdave]

I don't know, but as a survivor in your pics that bike looks pretty nice. They are only original once.

 

[theDQG]

The kind of PO everyone wishes they had.

 

[cycleranger]

I don't know, but as a survivor in your pics that bike looks pretty nice. They are only original once.

Yeah, I already threw those dirty mufflers away.

Heh, not really.

They are only original once and, imho, they're always worth more original.

The kind of PO everyone wishes they had.

No kidding. The PO bought the bike from his Uncle so it never left the family.

 

[cycleranger]

I decided I was tired of sitting on the floor so I spent 5 mins setting up a platform and continued the stripping. One can never have enough milk crates.

I was pleasantly surprised to find a Hella H4 conversion in the headlight bucket.
I hadn't noticed that before. However, there was bit of splicing in the headlight and the wiring harness is pretty crunchy after 40 years. I think a new one may be in order.
I'm also afraid the master cylinder might be a lost cause, but we'll see.

Check out those carbs, cleanest set I've ever opened!
Also, why can't I find any numbers on the carbs anywhere?

Time to break out the card and head over to Mike's....

 

[Brassneck]

I'm jealous of your bike...but maybe just a tad bit more jealous of your garage!

 

[TwoManyXS1Bs]

... the Yamaha shop/parts manuals kinda suck (imho) compared to the Honda ones.

Noticed that, didja? I try not to mention it.

...Also, why can't I find any numbers on the carbs anywhere?

Yep, you'll be with us for awhile. The past and senior members here have written tons on the carbs, and their variances, that you won't find in any manuals.

... Time to break out the card and head over to Mike's....

Caution there, too. Do your research in here before comitting to aftermarket parts.

The real secret is knowing the buzzwords to use for your forum searches.
For starters, try a search on "VM22/210"...

 

[650Skull]

here are some links specific to 76/77 BS38's.

http://www.xs650.com/forum/showthread.php?t=23881

http://www.xs650.com/forum/showthread.php?t=23880

http://www.xs650.com/forum/showthread.php?t=21117

http://www.xs650.com/forum/showthread.php?t=11980

Except for this one.
http://www.xs650.com/forum/showthread.php?t=21701

Genuine Mikuni Jets here.
http://www.jetsrus.com/

 

[fredintoon]

I'm jealous of your bike...but maybe just a tad bit more jealous of your garage!

Hi Brassneck,
no you ain't.
You'd only be jealous if the bike and the garage were yours and you didn't want to share.
What you are is envious
And ain't we all?
Nice bike, if it were mine I'd just ride it.
Nice garage, mine is way smaller with tools scattered all over and I hafta leave space for my wife's car.

 

[cycleranger]

Thank you all for the comments and information.
I will hit those links!

Yes, jetsrus, been there done that.

I do try to use OEM parts for the important stuff, where the parts are available. I only want to do this once...

But speaking of aftermarket, how are the Mike's wiring harnesses? Good? Or are there better alternatives?

As far as just riding it, well, it looked pretty nice in those 10-footer photos but up close it's pretty crusty. Pretty much needs all the rubber and wiring replaced not to mention hours of polishing. The PO serviced it religiously every 1000 miles so I'm hoping that I don't need to crack the engine any time soon...
(Although I may do the clutch since it's been sitting so long.)

TooMany, I'm down the road from you in Dripping Springs, I ride out in the area frequently.

I like to say I bought the shop and it came with a house.

Posted via Mobile

 

[650Skull]

Never heard a bad thing about Mikes harnesses, maybe the odd connector hasn't matched up, but all and all.

Some info on throttle shaft seals in those links, Mike's ones have had some bad reports.

If you need some diaphrams......http://jbmindustries.com/

 

[TwoManyXS1Bs]

Thank you all for the comments and information.
I will hit those links!

You're gettin' good stuff. Take eyeball pills.

TooMany, I'm down the road from you in Dripping Springs, I ride out in the area frequently.

Well, whattaya know. I'll be passing thru there on my way to Austin for the 'HandBuilt' show.

http://www.xs650.com/forum/showthread.php?t=44892

 

[cycleranger]

Well, whattaya know. I'll be passing thru there on my way to Austin for the 'HandBuilt' show.

http://www.xs650.com/forum/showthread.php?t=44892

I'll be there. Probably roll the CJ360T.

Posted via Mobile

 

[cycleranger]

Well, the fun part is over...
Finished stripping and got the engine on the stand.
I thought the steering felt a little notchy!
I'm pretty sure those bearings haven't seen new grease since 1975...
Tapered bearings are going back in.

Now I gotta decide on paint or PC for the frame.
The last two bikes I did PC but I'm leaning toward paint for this one.
We'll see.

Anyway, lot's o' cleaning, blasting, and polishing to do in the meantime!

 

[cycleranger]

Stripped the carbs today.
This where the JIS screwdrivers really make a difference.

Tomorrow everything gets soda blasted.

 

[cycleranger]

A quick question about the carbs.
These carbs have 127.5 mains, all else is stock. (Needle set to second notch)
I assume this deviation is because the the bike had pods.
(Or could this be factory? It's an early "C".)

I plan to go back to stock air boxes.
Can I make these 127.5's work or should I go back to the stock 122.5's?

Thx,

 

[5twins]

It appears the mains were increased two sizes and the needles leaned a step to "fix" the midrange with the larger mains. You will probably want smaller mains again with the stock airboxes, unless maybe you use K&N airbox replacement elements .....

These are very nice but expensive. They are a one-time expense though, as you just clean and re-install, never replace. They could work with the larger mains.

Watch eBay, you might score a deal like I did above. I noticed from the eBay photos that this airbox set had the K&N elements in them. I don't think the seller knew this. I got the whole package for about $30.

 

[cycleranger]

Well, that's funny because four years ago when I bought the bike I found a set of air boxes on ebay. I think I paid $40 after shipping.
When they arrived I opened them up guess what I found....
A set of K&N filters! I don't think the seller knew either.
I was planning on using them so for now I'll just leave those mains as they are.
Easy enough to change later if necessary.

Thx!

 

[cycleranger]

Does anyone know a source for these parts that doesn't charge $10+ each with $6 shipping?

For 34mm forks.
The ones I took out are more corroded than I prefer to reuse. Thx

Washer, Oil Seal
214-23146-00-00

Clip, Oil Seal
214-23156-00-00