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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

    Unfortunately I forgot to install the new Push Rod Bushing before I sealed up the crankcase.
    I don't really want to remove the new push rod seal that I just installed so I was just going to put in the new 1 piece push rod without changing the bushing, thinking I'll leave it till next time the seal starts to leak again.

    However when I look into/through the drive axle I can't see the existing bushing? Does anyone know if the bushing is visible to the naked eye?

    When installing the 1 piece rod is it just a matter of 1 ball bearing into the shaft, then slide the rod in and done?

  2. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    I had a productive 2 days. I removed the rocker arm shafts with a puller tool and cleaned out the last of the media. I managed to eradicate it. I know for the next engine the proper way to approach it. From the start tear the whole engine apart then blast the individual parts. I know where all of the oil passages are now and I can pretty much block them all plus cleaning them was easy. All hail brake cleaner. The shafts were really tough to get out and in.

    - I cleaned the shafts and arms.
    -I measured the specs on them
    -installed the rocker arms with the puller tool and it really helped to line up and get started into the bore, as well I used a hammer on it, great tool but a piece of 6mm rod and a nut would do the same thing. The shafts were really tough to get out and in so I'm glad I bought it.

    I lapped the valves. I found some paste that worked well, it had a multiple grits.
    My palms were so sore by the 4th valve that i could only use my fingers to spin it.

    I never figured out if i had a push rod bushing or not? so I'm saving the seal, I put in a one piece rod, it seems to have almost no movement side to side so I'll save the bushing till next time.

    I'll also put on my foot controls. I still have to tweek the rear brake and make a shifter.

    Tomorrow i'm installing the valves.

    Enjoy your evening.

    Attached Files:

    Raymond, gggGary and Jim like this.
  3. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    Early mornings the last 2 days as I try to complete the top end. I made a few screw ups today that slowed the process.

    -I started by cleaning the valve springs. Checking the specs.
    -Then using my cheap ebay compressor I installed the valves.
    -My cam chain is continuous so I removed the brace on the base of my cam tensioner arm by drilling the mount.
    -Installed the tensioner arm, I used Jim's idea of taping the screws to the driver, really helped. Jim's your top end write up was extremely helpful, many great tips. -Also Jim's taping the pistons idea and the blocks of wood (although I made them too short), really helped. My piston ring tool is garbage, I need to invest is something better for next time.

    Unfortunately I failed to notice that the Tensioner arm wasn't in the cylinder properly! I was so excited as I removed the wood thinking that I hadn't screwed up for a change. Doh!

    It all went downhill from here. I thought I could lift the cylinder slightly but popped the cylinder off! Thanks to Mailman for the popsicle trick, it worked.
    Then I thought that I had the tensioner arm in incorrect as It was rubbing inside the cylinder thankfully 5Twins set me straight. I should have quit right here for the day but I attempted to install the cam tensioner, the spec sheet says torque to 15pds for the cam tensioner and I snapped the bolt, it's obviously referring to another component.

    Tomorrow I will attempt to drill out the broken bolt, the replacement bolt will take 10days to arrive, just when I think it's almost done....

    Thanks Jim I hate to think what today would have been like if I didn't have your info for reference.

    Attached Files:

    Raymond, timbeck and Jim like this.
  4. Jim

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

    If you're referring to the chain guide bolt (last pic), you should be able to pick up that bolt at the hardware store... there's nothing special about it.
    Raymond and CrabbyCustoms like this.
  5. CrabbyCustoms

    CrabbyCustoms XS650 Enthusiast XS650.com Supporter

    That's great news. I just assume everything is so specific. I'm looking forward to not being such a rookie.
    Jim likes this.
  6. Jim

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

    Just takes practice. :D
    CrabbyCustoms likes this.

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