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1980 XS650 Brat/ Bobber/ Chopper/ Who Knows? Build

Discussion in 'The Garage' started by B_Crabaugh, Jan 4, 2019.

  1. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Definitely replace the camchain. Scuff marks, looks like it bowed to the side where the link pulled free. Check everything in the camchain tunnel, including the crescent hollow above the cam sprocket, for whatever damage.

    Close-up pics of that semicircular metal piece, sides and ends, may help us to identify it...
    Jim likes this.
  2. Superjet

    Superjet XS650 Junkie Top Contributor XS650.com Supporter

    Looks you are doing the exact same thing I did last winter. Replace cam chain and guide and entire new gaskets and seals. If you do buy cam chain from mikes it does come with a master link...they got me for an extra few bucks. Ensure you center the chain guide in the cylinders. Mine was not by p.o.

    I got the Athena kit cause it comes with the drain plugs gaskets. 5T mentioned that they last for a long time. I had a leak at the front plug and now no more! Good luck. JC
    TwoManyXS1Bs likes this.
  3. B_Crabaugh

    B_Crabaugh XS650 Addict

    Ok will do. Here is a closeup if that metal piece. There is an R etched into it. I’m pretty convinced it’s from an old piston ring. My bet is that this motor was once rebuilt to fix a compression issue and new rings were installed but a part of the old one was left floating around. There is gasket sealer EVERYWHERE and put on very thick.
    TwoManyXS1Bs likes this.
  4. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    I'll buy that. Keep a close eye on this'n. The oddities list is growin'.
    Somewhere in here is an old pic of a small screwdriver found wedged between crankcase webs, source and history unknown...
  5. B_Crabaugh

    B_Crabaugh XS650 Addict

    Houston we have a problem... Looks like the PO removed the mix adjustment on the carbs and managed to mangle the screw pretty badly. I took a free Harbor Freight 4-in-1 screwdriver that has a flathead that fits PERFECTLY in there, but no luck getting the thing loose. Soaked it in PB Blaster overnight, hit hith a hammer, and nothing. What to do?

    Got all my jets and whatnot from Mike's. Is this the correct order of operations for the jet needle? Seen here with the 5IX11.

    Cleaned up the motor pretty good with oven cleaner and a nylon brush. Still need to go over it again and get in the nooks and crannies with a toothbrush. I am certain that this thing has been apart before. Does this amount of gasket sealer seem heavy handed? I think so.

    Check out these screw heads. No way that's factory.

    How does this rear cam chain guide look? Serviceable? Is that a normal amount of wear for 10k miles?

    Is this clutch pushrod seal factory? I don't think so but could be wrong!

    I also noticed that this case bolt is missing...

    Here's a look at the crank. Turns smoothly and freely. Nothing is falling out. Look ok?

    Finally, here is one of the pistons. Looks ok to me. The rings look nice and were free. The rings on the other are stuck.

    On another note, I killed my first grinder! Do I get a badge?

    A little more cutting on the frame, then grinding, then sanding, then yada yada yada...

    Looking forward to your replies!
    Stardust83 and figure8 like this.
  6. Camilo

    Camilo XS650 Member

    Unfortunately looks like a case of someone trying to remove Japanese Industrial Standard screws with a Phillips driver. My bike looks very similar, tempted to replace damaged ones for new ones with hex heads.
  7. B_Crabaugh

    B_Crabaugh XS650 Addict

    Yep absolutely. Every screw on the bike looks like this
  8. B_Crabaugh

    B_Crabaugh XS650 Addict

    59Tebo likes this.
  9. B_Crabaugh

    B_Crabaugh XS650 Addict

    Update. Picked up this tank locally. Stock tank was pretty dented and I didn’t want to hassle with removing all the rust. Been there done that! It also needed the key and a gasket and new petcock. Got this bad boy for $40 and it’s very clean.


    Stared sanding it and some bondo was revealed, so looks like I’ll have some bondo of my own to do!


    Got it pretty much stripped. I used an abrasive wheel in my drill and a flap wheel on the grinder. Worked great except for some of the hard to reach spots. I’m also going to weld the bungs and add one to the bottom.



    Brought the frame, motor top end and wheels to the car wash. Spayed them with this Jasco stuff. Didn’t work great and I ran out before getting to the frame. Maybe it was due to the fact that the pressure washer used cold water? Who knows. Would not reccomend. I’m going to use aircraft stripper for the frame, now that I found some! Local autozone doesn’t have it but O’Riellys does.

    Drill brushed and hand sanded the wheels, focusing on the rim and where the bead and tube will sit. They are getting primed tomorrow!

  10. 59Tebo

    59Tebo 59Tebo Top Contributor

    Oh boy! Yer having fun now! The aftermarket tank will look very cool on a brat/bobber/whatever. :thumbsup: I don't know how I'm going to categorize "The Basketcase", either, but I'll need to do the old "paint stripper and carwash" trick myself. But right now, we're dealing with near-blizzard conditions, and over a foot of snow. :yikes: And it's still coming down. It's not just the snow, but the drifting is an even bigger problem! :doh: :offtopic:
    Moabite likes this.
  11. B_Crabaugh

    B_Crabaugh XS650 Addict

    Haha. Yeah I think at least as far as the “look” direction goes, I want a reeeeeal purty tank. Everything else will probably just get a quick refresh. When you are done with winter wonderland, I would maybe call local car washes and try and find one that has HOT water. Not sure if it made a difference, but I’m going to try hot water next time.
  12. 59Tebo

    59Tebo 59Tebo Top Contributor

    Hmmmm, nice idea, B. I was wondering, also, how much "steam" pressure comes out of an HFT steam (generator) cleaner:
    If there's enough volume coming out to hose off the stripper, and whatever finish you're stripping, this might be the ticket. Just be sure the run-off is going in a 'safe' place!
  13. B_Crabaugh

    B_Crabaugh XS650 Addict

    I have been eyeing one of those. Seems like it would work well. Maybe someone should buy one, use it and return it and make a video!
  14. B_Crabaugh

    B_Crabaugh XS650 Addict

    Gave the wheels a hand sanding and thorough wipe down. Taped off the areas I didn’t want paint on. Hung them in the garage with safety wire and a washer through the valve stem hole.

    First coat was rustoleum self etching primer.

    One can got both wheels covered. Then I switched to rustoleum primer sealer. It’s lighter in color so you can see where you are spaying which is nice.

    Went just a hair too fast, but only got a couple tiny runs. No biggie. Next step will be some silver, then masking, then black, then clear.

    Pulled the clutch and things are looking clean in there! The star gear neutral finder thingy looks to be in the right place too.



    There is some blue on the clutch springs. I’m guessing these are original? Was thinking of using Vesrah heavy duty springs. Anyone try those?

    Can this washer be reused? Or do I need a freshy?

    How do these clutch plates look? I’m not real sure how to judge their condition. They all look the same.
    Stardust83 and 59Tebo like this.
  15. 59Tebo

    59Tebo 59Tebo Top Contributor

    B_Crabaugh likes this.
  16. 59Tebo

    59Tebo 59Tebo Top Contributor

    Are you going for the monochrome (black) look on the wheels? You could restore the silver in the "spokes" with a roloc disc... :cool:
    Man, the P.O. really did get that sealer all over the place! :eek:
  17. B_Crabaugh

    B_Crabaugh XS650 Addict

    Tell me about it! Definitely not a light touch. Rolocs are great! I am doing something just a tad different with the wheels. Hard to explain so I'll just post some pics tomorrow.
    59Tebo likes this.
  18. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Some light reading:


    Daniel's clutch experience. Start at post #727.


    Robinc's clutch experience. Start at post #438.

    Tim Meaders and B_Crabaugh like this.
  19. cafetools

    cafetools XS650 Addict

    I live that red plastic cleaning tool for the drill. It seems to have the perfect amount of abrasiveness.

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