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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

    Well, I did not know that. Hmmm.....I’ll have to explore that further. Thanks Jim!

    Thanks Hotdog! I appreciate it, and believe me , I take no offense regarding the brain trust being a major contributor to my success. I relied on them heavily! :thumbsup: Thanks for checking in.
  2. It's been a real pleasure following your restoration Bob, congratulations on a beautiful bike and a story which I think will give future owners and old hands alike the inspiration to have a go.
  3. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Meddy! :)
    Jim likes this.
  4. jones5944

    jones5944 XS650 Enthusiast

    Bob: I wanted to let you know that you have done a great job of restoration and that your documentation is outstanding. Sometimes I feel like we are loosing younger and inexperienced people because they feel that they might be belittled or made fun of in forums like this. You have certainly been an exception to this. Please continue putting the information out there because a restoration is never completed. Thank you very much for the mention and I am truly honored to have had a small part in your adventure. I hope the seat foam will perform for many years to come. David Jones
    geedubya, gggGary, Jim and 6 others like this.
  5. Mailman

    Mailman Hardly a Guru Top Contributor

    David, I am absolutely delighted that you checked back to see my finished bike. Guys like you set the bar pretty high for the rest of us. And by the way, that seat is the most comfortable seat I’ve ever sat on. Thanks again! :thumbsup:
    geedubya, gggGary, Jim and 4 others like this.
  6. 650Skull

    650Skull SSSSSSSSSlither Top Contributor

    Congrats Bob..............Sure is a nice looking bike...........gotta be proud of this and thanks for taking us on the journey, sure we helped but you did the work. poor old 77 will be sulking in the corner...............says a lot about the build that when the right jet was installed that the bike started and ticked over like a watch, without any adjustment.........

    What do you say to collectively getting Travis to make or convert one of the forums into a dedicated ride forum..........some great rides have been posted and lost on here..........be nice to be able to read a dedicated collection......

    Ha, Ha, ha, it will take another year to make a prefix menu for the thread.............
  7. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Doug, I appreciate it. I’ve been having a blast with it.

    Not for long......:rolleyes:

    Hey that sounds good to me! I like following the guys on rides!
    geedubya, gggGary, Meddy and 4 others like this.
  8. Mailman

    Mailman Hardly a Guru Top Contributor

    Just a small update.

    The bike has 160 miles on it now. It starts, runs, idles and charges great , and it doesn’t do anything that worries me. It makes all the right sounds and doesn’t make any scary noises.

    I did the first oil change on it yesterday and there was a pretty good amount of metal flake in the oil and in the side filter. I am attributing this to the fact , that it has so many new parts in it, bedding in. I’m willing to bet that the next couple oil changes will see a significant reduction in sparkly stuff.

    I checked the timing and it was right on and advancing properly. I also adjusted the timing chain, which didn’t take much.

    I also took the time to go over the bike, looking for any loose fasteners, and I did find a few.....some valve cover nuts, and one that surprised me was the rear fender mount bolt,

    Under the fender is a rubber washer and a fender washer, lock and nut. I grabbed the fender and was surprised to see there was a surprising amount of movement. I looked underneath and the rubber washer had been chewed up from vibration? I replaced it with a thicker one. I may have overtightened the first one and damaged it during installation.

    Some first impressions

    The bike rides and handles really nice , but you can feel it squirm a little if you try to push too much speed going into corners. I believe most of that is due to the retro tire tread pattern of the Dunlop K70’s, also the 34mm forks probably have a little flex to them. The tires are also VERY wiggly when rain grooves are present.

    I have been a little surprised to see that despite the fact that every gasket and seal have been replaced, she’s still a dirty girl. Reminding me of my old Triumph Bonneville. Oil vapor seeps past the valve cover gaskets, my starter gear cover gasket , the base of the oil tube on the front of the motor, and don’t get me started with how messy the two crankcase breather hoses are. The underside of my bike was an oily mess. When I got the bike, the crud underneath was THICK. I can now see why, if you don’t stay on top of it. I may have to revisit putting some PVC valves or something down there.

    I was also a little worried about my cam shaft seals , if they would leak or not. I know some guys have had a lot of trouble. One side was bone dry, the other had just a really small drop of oil inside the housing, I can live with that.

    Mostly, I’m just enjoying riding it, and I hope it just gets better and better as the miles go on. :bike:

    WBacon, Superjet, MrBultaco and 9 others like this.
  9. Jim

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

    I've heard of a boy named Sue..... but a girl named Elvis? :umm: ;)
    WBacon, 2XSive, MaxPete and 3 others like this.
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    Haha! Oh yeah, I forgot I named this silly heap!
  11. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    I'll double-down ditto with you on that.
    Great all-around tires, but...

    When I cafe'd mine, Dunlop K-81s really Improved the corner handling...
    Superjet, Machine, 2XSive and 4 others like this.
  12. Mailman

    Mailman Hardly a Guru Top Contributor

    I ran K81’s on my 76 XS650, way back when. I still like them. :thumbsup:
    MaxPete, gggGary, Jim and 1 other person like this.
  13. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    MaxPete, gggGary and Jim like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    Yes exactly. The correct rubber washer is hat shaped (#26), so that part of the washer goes up into the mounting hole.
    TwoManyXS1Bs, GLJ, MaxPete and 2 others like this.
  15. GLJ

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

    How much side to side play does your fender have? I couldn't get the correct rubber dampers for the rear fender, so I used ones made for the battery box. For the top ones I added collars to hold them tight to the fender. I have no side to side play.
    It's important to keep an eye on the rear bushing.:doh:
    TwoManyXS1Bs, Jim, MaxPete and 2 others like this.
  16. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Yeah early rear fender mounts are pretty dodgy. most of my fenders look like GLJ's
  17. GLJ

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

    Luckily for me the one on the parts bike I bought was I good shape.
  18. Mailman

    Mailman Hardly a Guru Top Contributor

    The mounting hole in my fender hasn’t been enlarged at all. The way I have it now , the fender doesn’t move, but when I first grabbed it, it was very loose. It was probably close to losing the nut if I hadn’t caught it.
    TwoManyXS1Bs, Jim, MaxPete and 2 others like this.
  19. GLJ

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

    Sounds like your rings have not seated completely and you are getting a lot of blow-by past the rings. I only have 100 miles on mine but not seeing any oil leaks. I used nothing but red grease on the gaskets. I have both breather tubes wide open and the hoses are pretty dry.
    You restricted your tubes. That coupled with blow-by could cause pressure in the crankcase forcing oil past the gaskets.
    How have you been breaking the engine in?
    TwoManyXS1Bs, Jim and MaxPete like this.
  20. MrBultaco

    MrBultaco it ran before being parked Top Contributor

    What size tire do you have on the front? I know 3.25s aren't very good on rain grooves. They tend to track in them. That was the size I had on my 650 Seca and it wiggled all the way. Almost dangerous.
    Jim, Mailman and MaxPete like this.

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