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Crabby's Build

Discussion in 'The Garage' started by CrabbyCustoms, Jan 7, 2020.

  1. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    So I ordered my brake parts as well as new pistons and rings, Valve lapping tool and paste and valve seals.
    I'm sticking with my original caliper (because it looks so pretty) I glass bead blasted it and i'm going to seal it with a product I bought called ShineSeal. I plan to leave it unpainted. I will definitely test it fully before riding.
    February 25, 2020-49.jpg

    I also cleaned the cylinder head, I soda blasted the valve ports, then masked it off and abrasive glass blasted the aluminum exterior, then glass bead blasted to finish. I used boiling water to rinse (5 cycles) unfortunately the aluminum changed color again, I'm guessing its the heat? as the brake caliper didn't change when I cleaned it in warm water. I'm going to reblast with bead and try running it through the ultrasonic but with no heat. February 23, 2020-57.jpg February 25, 2020-40.jpg
    to the touch the valve seats fell smooth but they have a speckled appearance? hopefully when I lap them it will disappear.

    The question I have for anyone watching is regarding what I should do with the bottom end. I want to just clean it and build on top of it but it's such a mess. I cleaned with degreaser and a brush and it doesn't look like I did anything. I'm also worried that the main gaskets are leaking. Ideally i'd like to disassemble it and properly clean the cases but I don't know how realistic that is? I think i'm probably pushing my luck as it is?
    February 24, 2020-44.jpg February 24, 2020-50.jpg February 24, 2020-54.jpg
    Jim likes this.
  2. 59Tebo

    59Tebo 59Tebo Top Contributor

    That "mess" could be coming from the clutch rod shaft seal, the primary sprocket shaft seal, or both. Probably both. Replacing the seals is almost easier than cleaning up the mess. The back and bottom of the cases should be easier to clean. Then you can move on to the hardware on the bottom, especially the drain plugs. Nothing is ever quick, easy, or cheap. As long as you keep a good supply of elbow grease around, it'll get there. :thumbsup:
    Jim likes this.
  3. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Thanks 59Tebo! So do you think it's unrealistic to think that a total novice could completely take apart the bottom end and then actually put it back together?
    Jim likes this.
  4. Machine

    Machine Race the wind Top Contributor

    Watching, cheering and chiming in too.
    Firstly, I learned or rather just believed in my younger days that when taking on a unknown mechanical project such as an Austin Mini transmission, or a Honda CR engine/transmission, or a Chev Truck 400 ci V8 or most anything.. It will not go back together wrong. Somewhat a true statement. So yes, you could do the XS bottom end. Especially with the access to this site.
    Secondly, your bottom end is mostly oily and grimey on the left and down under so I agree that that mess was likely from that area. You may get away with out going to all the trouble and just finding and fixing the leaks. ?
    Of course I do not know of your time frame wanted or your shop amenities.
    CrabbyCustoms and Jim like this.
  5. 59Tebo

    59Tebo 59Tebo Top Contributor

    Definitely NOT unrealistic! With your manuals at hand, following the pictures, and following the articles on this forum, it is absolutely doable! I'm not saying it'll be duck soup, but you sound like you have the wherewithal to accomplish this with stellar success. However, whether or not you need to split the cases is a different story. A set of seals and a top end gasket set would go a looooong way to drying up that motor and keeping it that way. There are excellent articles in the "Tech" section (see the bar above) covering both jobs. Break each assembly into the steps required, and you will prove the whole to be greater than the sum of its parts. Cripes! I sound like a fortune cookie! :doh:
  6. Jim

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

    First, let me state the obvious.... next time, thoroughly clean the motor before disassembly. :rolleyes:
    If your only reason for taking the bottom end apart is to clean it, I wouldn't. Like Tebo said, lots of elbow grease will get it clean.
  7. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Everyone, thanks so much for all of your help, your kindness and dedication is really appreciated.
    And you've answered my questions definitively. Why tear into it if it's unnecessary. My OCD is bubbling to the top, I want the bike to be perfect but I need the bike to be finished so I do have a time frame, as well I've run out of space, all the cleaned parts are covering my basement so I don't really have enough space to do it anyways.
    I'm going to attempt to just clean it and fix the the clutch rod shaft seal and the primary sprocket shaft seal. Thanks for that.

    We had a bit of a warm up last Saturday so I took a photo of my daughter Bonnie with my rolling chassis. Time to get an engine in it.

    February 22, 2020-72-Edit.jpg February 22, 2020-55-Edit.jpg
    LanzSilva, Team Junk, 59Tebo and 3 others like this.
  8. Machine

    Machine Race the wind Top Contributor

    Aah, nice ! Girls and bikes do go together so well :)
    LanzSilva, gggGary, 59Tebo and 2 others like this.
  9. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Just trying to remove the clutch plate but the basket spins and I can't get traction on the spring screws. After searching the site it appears an impact driver is the ticket but I just want to confirm this as I'm worried about spinning my connecting rods and having them hitting against the crankcase.

    Jim likes this.
  10. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    Impact is necessary.
    Also get some rubber bands.
  11. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    It's been awhile since I've been able to work on the bike. Life here is a little crazy as I'm sure it is for all of you (Wherever you all are!?) I hope everyone is staying safe.
    Trying to entertain my wife and kids has become a full time endeavor but last week I was able to eek out a little bike time and have started to move forward with cleaning up my engines bottom end.
    I started with a trip to the local retailer to pick up some cleaning fluids.
    February 26, 2020-50.jpg

    The Gunk engine degreaser GEL worked really well, it's water soluble so easy to use and did an amazing job of cutting through.

    March 20, 2020-7.jpg March 21, 2020-22.jpg March 21, 2020-25.jpg

    the bottom of the engine proved to be the most difficult area. Really baked in.

    March 22, 2020-28.jpg

    Once I had the majority of grease off I masked it up and blasted it in my back yard with Abrasive glass. Very messy but it did a good job of removing some of the corrosion.

    April 05, 2020-11.jpg
    Tomorrow I will be setting up in the yard again to give it a 2nd stage blast using Glass Bead. I'm nervous about using blast media as I know some will end up finding it's way inside the engine regardless of how careful I think I am. When searching in the past I found a thread where people discussed cleaning out the bottom end with a solvent, (pouring it in the oil imput and swishing around then draining out and repeating)but I can't remember which solvent they recommended? Acetone? maybe Kerosene? I can't seem to find the post now. Any ideas? Thanks!

    I also got a headlight and installed it.

    Screen Shot 2020-04-05 at 1.14.53 PM.png

    (My kids won't leave me alone!) Screen Shot 2020-04-05 at 1.11.00 PM.png March 28, 2020-6.jpg
  12. 5twins

    5twins XS650 Guru Top Contributor

    Kerosene is my cleaner of choice for most everything. I don't bother with those fancy specialty engine de-greasers, no need to. Yes, it will work fine for rinsing the inside of the engine out.
    Mailman and CrabbyCustoms like this.
  13. Jim

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

    I'd put the jugs and head back on. No pistons or innards, just the outside. Valves will stay closed, plugs in and points and advance covers on (heavily taped on the chrome). It'll keep the beads out and you get to clean up the top end too.
    Mailman and CrabbyCustoms like this.
  14. Rasputin

    Rasputin XS650 Addict XS650.com Supporter Top Contributor

    I once had the envious task of cleaning a Austin Mini engine, being stingy I acquired a large tub of hand cleaner from work, Fast Orange with micro beads. Applying it liberally to the engine with a large brush and working it well in then leaving for half an hour, when hosed off I was really surprised at the result.
    These days my degreaser of choice is Elbowgrease, bought at the cheapo retail outlets, Poundland etc.
    This cleaner is marvellous does what it says and, leaves your polished aluminium bright and shiny.

    Attached Files:

    gggGary, TwoManyXS1Bs, 59Tebo and 3 others like this.
  15. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    I finished blasting the bottom end and it looks pretty good. It's amazing how good you can make it look after 42 years!

    April 20, 2020-14.jpg March 22, 2020-28.jpg
    April 20, 2020-28.jpg
    I also treated the aluminum with a product called Shine Seal which apparently cuts down on oxidation.
    April 20, 2020-2.jpg

    I also started looking at the carburetor. The needle and diaphragm assembly move freely but the butterflies are stuck, I'm assuming this (throttle or choke?) should open them easily.

    April 20, 2020-17.jpg

    Anyone know which Carb this is?

    April 20, 2020-20.jpg
    I put my starter motor to a battery and it seems to run fine. Tomorrow i'm dissembling to clean and inspect it. Then start to rebuild top end.
    TwoManyXS1Bs, Raymond and 59Tebo like this.
  16. Steveair2

    Steveair2 XS650 Addict

    Nice work! Your doing a great job. Can't believe how good the soda blasted motor looks. I soda blasted an airplane frame in my back yard onetime.
    Killed all the grass where I was working. My wife was pissed. It grew back after a few years. Thanks for sharing your project.
  17. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Hahaha I did the same thing. Thanks Steveair2 for all this info, I've been reading the pdf. It's a goldmine.
  18. Steveair2

    Steveair2 XS650 Addict

    Your welcome, I didn't get any carbs with my donor bike so I'm still trying to figure out this out too.
    I bought a few sets off Ebay but I still don't really know what I have.
    CrabbyCustoms likes this.

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