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1981 Yamaha XS650S - Project Bike #5

Discussion in 'The Garage' started by rbirkey, Aug 3, 2019.

  1. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    I'm not certain how lengths of forks compare, however, XS750, XS850, and XS1100 all have the double banjo bolt coming out the bottom as you describe. I have not physically looked at the bikes, but EU and Oceania market XS650 have dual disc brakes and I would assume the junction is in the same place. Some folks move the double to the MC. Speaking for myself, I would rather not add the extra length of line.
     
    Mailman and Machine like this.
  2. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi marty,
    the book sez the stock hoses have a 5 year lifespan so it's best to replace them anyway.
    My dual front conversion uses two stainless steel wire reinforced plastic hoses from the lever to the calipers.
    Left-side caliper was salvaged from an XS750 Standard.
     
  3. Paul Sutton

    Paul Sutton Still Looking Good Top Contributor

    Anyone know the life-time rating for the modern brake hoses?
     
  4. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    If the four year hoses have lasted 40 years, it seems most of us won't live long enough for it to matter.
    :laugh:
     
  5. 5twins

    5twins XS650 Guru Top Contributor

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    Yes, I don't think you ever have to worry about the braided stainless ones wearing out or going bad. I've been using them on all my bikes, some for probably more than 30 years, and never had any go bad.
     
  6. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    Ive had 18 year old BMW MC hoses that were junk, leaking, not uncommon for that brand.
     
  7. 5twins

    5twins XS650 Guru Top Contributor

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    The jury is still out on the cheapo China braided lines I've been using lately. So far they're good but it's only been a couple of years.
     
  8. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    Think Theres a good 6-7 years on some of the banggood lines I installed. Madness has aeroquip lines, from the 80's?? going strong.
     
    Jim likes this.
  9. rbirkey

    rbirkey TriumphBonneville.org

    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 hole in the bottom. Working the lever causes rippling of fluid in the master cylinder, and there is maybe a little resistance. But, not matter how much I work the lever, or even if I try to power suck fluid through the bleed valves using an air compression brake bleed tool, I get no fluid or air. It's the weirdest thing I've ever seen.
     
    Mailman and jetmechmarty like this.
  10. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    BTDT, got the T-shirt. Don't give up you'll eventually get the air out.
     
    Mailman likes this.
  11. CaseyH

    CaseyH XS650 Enthusiast

    What I have done is go to a farm supply store and get a animal syringe and pump brake fluid from the caliper to the master cylinder.
    Works well
    Just have to be careful not to spill if the master cylinder fills to full.

    Casey
     
  12. rbirkey

    rbirkey TriumphBonneville.org

    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 the system.

    I've also installed a new flasher unit and successfully wired up new TruWrapz 360 LED Turn Signals I purchased from Dime City Cycles. The rear flexible LED taillight-turn signal-running light strip is also wired up and working, but I am waiting on a replacement from MikesXS... the one I received had a dead section.

    truwrapz-front-signals.jpg

    flexible-taillight-LED.jpg
     
  13. rbirkey

    rbirkey TriumphBonneville.org

    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!

     
    Paul Sutton, 88_pony, timbeck and 3 others like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    Well done! It came out great!
     
    rbirkey and Jim like this.
  15. rbirkey

    rbirkey TriumphBonneville.org

    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 instruments wiring, then take it for its maiden voyage spin!
     
    Paul Sutton, GLJ and Mailman like this.
  16. Paul Sutton

    Paul Sutton Still Looking Good Top Contributor

    Very nice!!! Great when they startup so smoothly :smoke:.
     
  17. rbirkey

    rbirkey TriumphBonneville.org

    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 - suspension feels mushy
    shakedown-ride.jpg
     
  18. 5twins

    5twins XS650 Guru Top Contributor

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    With rubber brake lines, the brakes may always feel mushy, lol.

    These forks work better with a little bit more than the stock amount of oil in them. Stock spec is just under 6 ounces per leg. Run 6.5 to 7 ounces per leg. The forks won't feel as mushy and they'll dive less when braking.

    Those tapered and pleated style pods may cause tuning issues. That type of pod doesn't work well on CV carbs. If you're going to use pods, the straight foam UNI's are the best choice.
     
    rbirkey and Paul Sutton like this.
  19. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi rbirkey,
    fix the mushy brake feel by swapping in stainless steel wire braid reinforced brake lines.
    They ain't cheap, run two long lines from the lever to save 1/3rd of the cost. AND drill the brake disks.
     
    rbirkey and Paul Sutton like this.
  20. Paul Sutton

    Paul Sutton Still Looking Good Top Contributor

    No one has mentioned "Banggood" brake lines.
     
    Mailman and gggGary like this.

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