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Mailman’s XS2 a full on restoration

Discussion in 'The Garage' started by Mailman, Mar 1, 2018.

  1. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Pete!
     
    Jim likes this.
  2. hotdog

    hotdog XS650 Guru

    100 pages of quality documentation , congratulations.
     
    Jim, gggGary and TwoManyXS1Bs like this.
  3. Mailman

    Mailman Hardly a Guru Top Contributor

    Holy Cow! Sure enough! And darn near 2,000 replies! 32 days short of one year since I started.
     
    Jim, gggGary and TwoManyXS1Bs like this.
  4. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Great progress there, Bob. Glad that the brake stay bolt clears.

    Really enjoying your restoration. What amazes me is the time machine effect this is having on me. Long forgotten 40+ year-old shop memories occasionally resurface, and another one popped up.

    I recall doing front-end rebuilds, and used this shop sequence with the headlight shell.

    - Spread the ears outward, out of the way, and avoiding scratching the headlight shell.
    - While holding the shell, pointing downward, with one hand,
    - Thread all the wiring into the shell, with the other hand.
    - Bring the shell up, swing the ears back in,
    - Fit the turn signal stalks.

    I know, a bit late with this, but thanx for the memories...
     
    YamadudeXS650C, Jim, GLJ and 4 others like this.
  5. 59Tebo

    59Tebo 59Tebo Top Contributor

    Fantastic job, Mm. :rock: This has been like watching one of those car restoration shows (in slow motion), where the resto is better than factory new. Your work is meticulous! :cool: After this, turning a barn-find into a fully functional runner will be child's play! :bike:
     
  6. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Tebo!! Slow motion is the right description all right! I appreciate the comment. Haha!

    [QUOTE="TwoManyXS1Bs, post: 579190, member: 14703]
    I recall doing front-end rebuilds, and used this shop sequence with the headlight shell.

    - Spread the ears outward, out of the way, and avoiding scratching the headlight shell.
    - While holding the shell, pointing downward, with one hand,
    - Thread all the wiring into the shell, with the other hand.
    - Bring the shell up, swing the ears back in,
    - Fit the turn signal stalks.
    .[/QUOTE]

    Thanks Steve, I have already had the thought that that headlight shell may have to be loosened up to wrangle all the wires in. I might have to pop the grommets out also to fit the bigger multi plugs inside. I’m happy you’re enjoying following along with me.
     
    Last edited: Jan 29, 2019
    Jim, TwoManyXS1Bs, GLJ and 1 other person like this.
  7. kshansen

    kshansen XS650 Junkie Top Contributor

    707
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    Bob, got a deal for you! Save all those nice labeled containers and when the `72 is done I'll ship the `78 that is out in my garage down for you to do next!
     
    Jim and GLJ like this.
  8. Mailman

    Mailman Hardly a Guru Top Contributor

    And deprive you of all that fun? Haha! When this bike is done, I’m taking a vacation! ;)
     
  9. 5twins

    5twins XS650 Guru Top Contributor

    17,755
    7,549
    688
    And on the bike I hope, lol.
     
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    I will definitely be going riding on this bike! It’ll only be this clean once!
     
    geedubya, TwoManyXS1Bs, GLJ and 2 others like this.
  11. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    After your vacation you could start a thread on bike washing, waxing and periodic detailing. We don't have enough of those kinds of threads.:)

    Scott
     
    GLJ and Mailman like this.
  12. Mailman

    Mailman Hardly a Guru Top Contributor

    THIS WAS A GOOD DAY.......

    Not so much because I accomplished a lot, I didn’t really , but because today just made me happy.

    I got to install a couple items that have a lot of meaning to me, not really for what they are but what they represent.
    Everywhere I turn on this bike I will see reminders of the friendships I’ve made here and the generosity of the members of this forum.

    So let’s get right to it. I started out with a simple task. Install my Grand Tourismo knock off handgrips. I had the real deal on my bike back in the seventies and also it’s what was on this bike when I bought it. I kinda have mixed feelings about these new grips. The real ones have a sort of slick almost plastic feel to them. The new ones are made by Emgo and are a very soft and rather squishy rubber. They will probably do a great job of damping vibes, but the jury is still out on them. Psssst......don’t tell my wife I snuck into her cabinet and stole her hairspray. It’s my adhesive of choice.
    2E21EEF9-ACA7-467F-9E5F-3D6DB4FF542B.jpeg

    So grips are on and my freshly repainted clutch lever perch is on
    038E3428-50C0-40EA-A519-E5A88C3443EC.jpeg CCCCC41A-EEDC-4C81-B2EB-0C4FFAE84016.jpeg

    Which brings me to my first highlight of the day. My little left handlebar switch. Boy oh boy what a sorry mess this was when I first got my bike. I honestly thought it was beyond being salvaged.
    ADA12FA9-D88A-42E9-91DB-1FFF1A8BF81F.jpeg

    It was broken, missing internal parts, full of gunk and completely inoperable.
    2734C656-9275-4DFF-ABA3-68BA4CBD8333.jpeg 6457CC8B-94DB-4533-8B93-64F82868CC7D.jpeg C50B9670-20E0-4DDA-888B-7934EEF559DD.jpeg 1606CCC3-6277-4160-8348-9A496685B5D8.jpeg

    In fact I ordered a knock off left hand switch that was designed for early Yamaha enduros. It looked right but had a lot more wires than my switch and the switches worked differently and all the wire colors were different. I’m not great with wiring and it had smoke coming out of my ears so I figured I’d take a shot at refurbishing this one.

    BIG SHOUT OUT TO KEN HANSEN AND DANIEL BLACK!!!
    8F980264-05FA-4261-8285-48E8223EDE85.jpeg
    They really came through for me. Ken had the unobtainium sliding switch and other internal parts, and Daniel supplied me with an entire switch from a later model 650 which I robbed springs and tiny ball bearings from. After much cleaning and scrounging and lubricating and piecing together and literally weeks of time. I cobbled together the switch you see here. Genuine XS2! Thanks guys, you rock!
    27EF52A9-7219-4D1B-937A-EEE63EF2A7B7.jpeg

    Now mind you, I will probably never ever use the headlight high -low switch because it is a poor design and the post that the sliding button is mounted to is WAY too fragile. It was a common failure on these bikes. I found that out when I was shopping for used switches on eBay.

    Now on to something that I’m REALLY EXCITED ABOUT!!

    Notice anything different?
    F09A9AD3-AD27-4273-9AE8-D3D0FFEE20A2.jpeg

    Look what I’ve been squirreling away for months now!
    D622B108-FC58-4693-83FC-77400F1C756A.jpeg

    I have been salivating over this ever since I first read 2M’s post about making them. Here,

    http://www.xs650.com/threads/custom-aluminum-steering-damper-for-70-73-xs1-xs1b-xs2-tx650.45956/

    As soon as I bought my XS2 I knew I wanted me some of that eye candy. I contacted Steve and we worked something out, he got my first born grandchild and I got MY PRECIOUS! Haha! :D

    I spent a lot of time screwing around with it, trying out different finishes on it. I tried to do a brushed satin finish which I actually thought looked pretty good, then I clear coated it and for whatever reason the clear lifted.
    So I fell back to what I know. 1500 grit wet sand and blue magic then buffed. I love it. :heart:

    I was going to wait until the final reveal on the finished bike, but I was like a kid at Christmas and it had to go on!
    I have huge respect for Steve and having one of his prizes means a whole bunch to me!
    THANK YOU STEVE!
    2CFFD360-69A2-433C-A338-0B62BAB15A43.jpeg

    Until next time,
    Just call me 3M :laugh2:
     
  13. GLJ

    GLJ If you can't laugh at youself you shouldn't laugh Top Contributor

    Now the hardware looks even worse. How will you sleep.:lmao:
    91.PNG
     
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    You know you had me looking at that today, hmmm.....I wonder what time the hardware store opens?
     
    GLJ, geedubya and Jim like this.
  15. 59Tebo

    59Tebo 59Tebo Top Contributor

    Do they open at Polished Stainless button-head Allen screws o'clock tomorrow? :laugh:
     
  16. cra-z1

    cra-z1 XS650 Junkie

    697
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    Idaho
    Go for the stainless steel phillips head hardware and washers
     
    Mailman likes this.
  17. 5twins

    5twins XS650 Guru Top Contributor

    17,755
    7,549
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    The thing is, I think those are J.I.S. screws. The heads are a slightly smaller diameter than a normal metric Phillips. Off-the-shelf replacements probably won't match. For a perfect match, you might have to get them from Yamaha but gosh, they're expensive .....

    https://www.partzilla.com/product/yamaha/98580-05020-00?ref=54861a18395ebf342cb931f246256baf086f0b90

    ..... and who's to say the screw they're selling now will even match an original. I guess it's worth a shot to try a hardware store screw.
     
  18. Mailman

    Mailman Hardly a Guru Top Contributor

    Yeah, I’m not a slave to being absolutely correct. I’ll go see what they’ve got. :)
     
    GLJ and Jim like this.
  19. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Oh-ho, Bob! That left handlebar switch looks great. And, the steering damper knob looks great too, surrounded by your meticulous restoration efforts on the instruments and front end. Glad, and proud, to have it on such a pristine machine.

    An undocumented feature, after sufficient break-in, the tuning fork will point towards BBQ...
     
    WBacon, YamadudeXS650C, GLJ and 5 others like this.
  20. Mailman

    Mailman Hardly a Guru Top Contributor

    Now that’s. Bonus! Haha! Thanks Steve!
     
    GLJ, 59Tebo, MaxPete and 1 other person like this.

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