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22's 1980 xs650 build thread

Discussion in 'The Garage' started by Twenty2, Jan 27, 2021.

  1. Twenty2

    Twenty2 XS650 Addict

    Ah okay, will definitely do that.

    Hit a snag tonight, took the bike off the jack finally, pulled the clutch in, went to roll it and it wouldn't, it was in gear and as if I didn't have the clutch pulled in. Does this mean I need to adjust the clutch even though I didn't change the cable or change anything? I cleaned and greased the worm gear but I put it back together the exact same as it was before. If this is the case, that nut on the screw is damnnn tight as I tried to remove it previously and decided against it cause I felt like I was going to damage it.
     
  2. 5twins

    5twins XS650 Guru Top Contributor

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    Yes, sometimes when you take the worm apart, when you put it back together it needs to be adjusted again. You'd best get that lock nut freed up on the adjuster screw because clutch adjustments are something that needs doing from time to time. Once you free it up, liberally anti-seize the nut and screw. They're just raw steel and often seize up. Also, when tightening the lock nut, you needn't make it super tight. Tight yes, just don't go ape shit on it, lol. A 12mm offset box wrench works well for loosening and tightening the lock nut .....

    [​IMG]

    You can buy just the one wrench off eBay .....

    https://www.ebay.com/itm/132905551009?var=&hash=item1ef1c9c4a1
     
    Twenty2 likes this.
  3. Twenty2

    Twenty2 XS650 Addict

    Thanks, I managed to break the nut loose after letting it soak overnight, I did it in place on the bike but without the cable hooked up, the worm gear turned but eventually it stopped and the nut finally snapped free with a big snap.... hoping I didn't damage anything, it looks like the little tang that folds over and holds the cable in place is bent pretty bad but that's fine, mind you, I'm guessing it will only stand being bent back and forth so many times before breaking off. I used a socket but that offset wrench would have been handy, I'll look into getting one, thanks for the link!
     
  4. 5twins

    5twins XS650 Guru Top Contributor

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    Honestly, I don't mess around with bending that retaining tab back and forth all the time. I have it bent partially open, enough to get the cable in and out, and just leave it at that. I've never had an issue with the cable popping out .....

    [​IMG]
     
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  5. Twenty2

    Twenty2 XS650 Addict

    I've been for the most part super careful and gentle with all the old bolts and nuts but somehow today I managed to damage one of my exhaust studs, I'm not sure if it was the nut or what it was but either way it looks like I need to buy a die set, can someone confirm that I need a 10mm die with a 1.25 pitch? Also, I measured the stud after I broke the nut loose and it's about 1mm shorter then the other 3.... I'm assuming when I was tightening it and the nut got stuck I spun the stud into the head a mm or so, for piece of mind can someone tell me that I didn't do any damage and that I can just back it out a mm and call it good?
    Also, ill check the nuts threads, worse case scenario I buy a set of 4 new ones from 650direct for $12.....
     

    Attached Files:

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  6. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Last edited: Aug 15, 2021
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  7. Twenty2

    Twenty2 XS650 Addict

    Interesting.... I didn't know that tool even existed, thanks!
     
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  8. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Try it, you'll like it. :smoke:
     
    Mailman, gggGary, Mikey and 2 others like this.
  9. 5twins

    5twins XS650 Guru Top Contributor

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  10. 5twins

    5twins XS650 Guru Top Contributor

    21,925
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    Again I'll mention the anti-seize. You should be using this stuff on pretty much every fastener on the bike, but especially on those hot exhaust studs. Anti-seize basically comes in two versions, nickel-based which is silver in color and copper-based which is copper colored. Many years ago when I first bought it, they had both. I compared the cans and the temp ratings were pretty much the same so it really just came down to a color choice. I figured the copper stuff would show up better on the mostly silver colored screws I was going to use it on so I went with it. I've never changed and still use it to this day .....

    [​IMG]

    [​IMG]

    It's like the old saying about taking a dump - "The job's not finished until the paperwork is done". When it comes to motorcycle mechanics, anti-seize is the "paperwork", lol.
     
    gggGary, Twenty2, Jan_P and 1 other person like this.
  11. teamWicked

    teamWicked XS650 Addict Top Contributor

  12. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    No, you can use a die... or you can use a thread file. The nice thing about a thread file is it covers an infinite range of diameters. You don't need a separate die for each size bolt.
     
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  13. 5twins

    5twins XS650 Guru Top Contributor

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    ..... and you can fix just one little spot if need be.
     
  14. teamWicked

    teamWicked XS650 Addict Top Contributor

    I see that. Often, for me the spot that needs fixing is the end. Then I take the bolt to a disc sander and gently roll a bevel.
     
  15. Twenty2

    Twenty2 XS650 Addict

    So while waiting for the thread file to arrive I decided to empty all the old gas from the tank, which made me wonder what does one do with old gas aside from start a bonfire? Anyways after emptying the gas I found what I'm guessing is the petcock filter loose in the bottom of my tank... I'm looking for advice for my next move? The petcock currently works perfectly, prime shuts it off. My fear is that if I take the petcock off to reinstall the filter I'll probably end up with a leaky seal and possibly need to completely rebuild the petcock, any advice would be great!
     

    Attached Files:

  16. teamWicked

    teamWicked XS650 Addict Top Contributor

    Pour your old gas into your lawnmower. 10-30% old gas in each tank. Old tractor, old outboard, old car.... anything you use often but avoid any high compression ratio motors. My lawnmower gas (left over) goes into the snowblower. Then the snowblower gas (leftover) goes into the lawnmower. The outboard gas gets used in winter too. I buy 1 gallon at a time so that end of the season gas, summer or winter, is still pretty fresh.
     
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  17. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Filter also contains the stand pipe so you have reserve and main tanks. Leaving it off means no reserve.
     
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  18. Twenty2

    Twenty2 XS650 Addict

    Hmmm sounds like I need more engines.... I like that idea!
     
  19. Twenty2

    Twenty2 XS650 Addict

    Well I definitely want reserve so I guess I'll take the chances with removing my petcock and hoping it seals back up well.
     
  20. Jan_P

    Jan_P XS650 Guru Top Contributor

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    I dont think it will be any problem
    I remove mine every year when I empty the tank for winter.I Put some oil in tank -- that needs to come out
    If you are nervous you can replace the 20 rubber ring I don't do that I smear some liquid gasket slop
    on it
    Never noticed any leaks

    upload_2021-8-20_22-1-35.png

    upload_2021-8-20_21-54-52.png
     

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