1. Dismiss Notice
  2. Hey Facebook people... We've created a group for XS650.com members to connect. Check it out!
    Dismiss Notice

Mailman’s XS2 a full on restoration

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

  1. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Ozboy,
    us Canadians got binumeral tapes, fractional inch above decimal metric so we can make two different wrong measurements at once.
    Like the Gimli Glider. That aircraft ran out of fuel just east of Winnipeg and they glided all the way to an abandoned airstrip in Gimli MB.
    The error was mis-reading the fuel tank drop tubes. The screwup was not recognising that the only safe way to fly when your aircraft's
    fuel gauges ain't working is to say "screw the economics and top off the tanks"
     
    Ozboy, TwoManyXS1Bs and gggGary like this.
  2. geedubya

    geedubya geedubya XS650.com Supporter Top Contributor

    G'day,

    There are only three countries in the world which are not metric, USA, Burma (Myanmar), and some rinky dinky small country in Africa.
     
    Jim, Rasputin, Ozboy and 2 others like this.
  3. peterg

    peterg XS650 Addict XS650.com Supporter

    350
    306
    63
    Canada
    The African country is Liberia.
     
  4. scanney

    scanney XS650 Enthusiast

    Can you assist with some instruction in replacing the stock steering head ball bearings with tapered bearings from Mike's? My first time and I need some re-assurances. I too have been blessed with a '72 XS2! Thanks
     
    Jim and gggGary like this.
  5. Rasputin

    Rasputin XS650 Addict

    I’ll have you all know we in the UK are Bidimensional. We have Metric hammers and Imperial hammers.
     
  6. Mailman

    Mailman Hardly a Guru Top Contributor

    First of all Scanney, Welcome to the mad house! I hope you will enjoy working on your new XS2 as much as I do.
    In fact I just got home from a little 75 mile ride this morning. I see you found my XS2 rebuild thread, it’s a long one, but skip through the chit chat and there is some good info in here.
    Regarding your steering head bearings, I’ve written this up before, here are some links you can read with lots of how to photos, from my ‘77 build, but the bearings go in the same way. The hardware on top of the steering yolk is different is all. ( By the way, the search window at the upper right part of the screen is your best friend, pretty much anything you could ever hope to do is in this forum! ) Good luck and think about starting a build thread in the Garage for your bike, and let me be the first to say— We like photos! :geek:
    Bob

    post#647
    http://www.xs650.com/threads/my-60th-birthday-present.47639/page-33#post-506277

    Post #686
    http://www.xs650.com/threads/my-60th-birthday-present.47639/page-35#post-507177

    This link is an instructional from the All Balls bearing Co.
    https://www.cyclepedia.com/manuals/...-intallation-guides/steering-bearing-upgrade/
     
  7. Jim

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

    CharmingScentedKinkajou-small.gif
     
  8. scanney

    scanney XS650 Enthusiast

    Thanks Mailman, this is good stuff. This is my first attempt at removing and replacing steering bearings. I don't want to f this up on such a cool bike.
     
    Jim and Mailman like this.
  9. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Rasputin,
    all us Brits and former Brits have those, and mallets besides.
    But do you have a Whitworth Crescent Wrench?
     
    Last edited: Dec 10, 2019
    geedubya and GLJ like this.
  10. Jim

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

    We used to call 'em "japanesefitalls." ;)
     
    TwoManyXS1Bs and geedubya like this.
  11. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Rasputin,
    but if you ain't got a Whitworth adjustable spanner you are just an amateur, eh?
     
  12. azman857

    azman857 '80 XS 650SG Rider Top Contributor

    Does "Decimalization" ring a bell. I heard it in '78, when I got assigned to RAF Lakenheath .
     
    Jim and gggGary like this.
  13. 59Tebo

    59Tebo 59Tebo Top Contributor

    Is that the same as a "Several sixteenths" wrench? :laugh:
     
    TwoManyXS1Bs, geedubya and Jim like this.
  14. Rasputin

    Rasputin XS650 Addict

    Yes. I have those too. But don’t consider myself as anything but a complete amateur, even after 45yrs in the mechanical trade.
     
    Jim likes this.
  15. Norton7d

    Norton7d XS650 Addict

    Nice Mailman, your "your roadmap" provides alot of help to us fellow explorers.
    Question, why the cork in the bottom of the lower triple, grease cant come out the shaft, can it?
     
  16. Mailman

    Mailman Hardly a Guru Top Contributor

    The cork your asking about , plugs the open bottom of the triple tree. Yes the shaft has an open notch in it for the steering lock to catch in. Grease could migrate through that notch and exit the bottom of the triple tree.

    Here you can see the steering lock notch in the steering stem. ( I had to remove the vinyl tubing because of clearance issues. ). Also note: I could not use a grease zerk in my XS2 because it has a friction damper at the bottom of the steering head which would be useless if it got greasy. )
    7FC460F3-D41E-4869-BBFB-5170CEC87569.jpeg
     
    TwoManyXS1Bs likes this.
  17. Norton7d

    Norton7d XS650 Addict

    Thanks, the moment I pressed "enter, I realized with the grease zerk mod, the pressured grease would fall into the "drain" of the lock assembly receiving hole....duh!
    On a side note, are u sure your order of parts regarding headlight bracket are correct?
    Doesnt the large chrome cover go at the bottom of the parts progression, with the small chrome ring and rubber gasket go on top of the chrome cover, as shown in this parts diagram, parts 14, 15, and 16?
    After seeing this diagram, its the order I chose, which may or may not be correct.
     

    Attached Files:

    TwoManyXS1Bs likes this.
  18. Mailman

    Mailman Hardly a Guru Top Contributor

    Well , I’ll be. I did this job a year and a half ago. I had to go back and look at my old posts. Here is a photo of the assembly prior to tearing it down. I just kept things the way they were, but yours looks to be the correct order. Hmmm...
    B948CF47-7781-47F1-9D68-89140431BC3C.jpeg
     
    TwoManyXS1Bs likes this.
  19. Norton7d

    Norton7d XS650 Addict

    Part of my thinking was, if the outer chrome cover went over all other parts, there wouldn't be a reason for any chrome parts under the cover if they aren't seen?
    Also, my rubber gasket had indented female bumps which can be seen on the inside of the chrome ring under side as male bumps, thus it appeared this was the order and the bumps transferred after years of being in place under load.
     
    TwoManyXS1Bs and Mailman like this.
  20. scanney

    scanney XS650 Enthusiast

    Hello Bob,
    I've successfully removed the original bearing cups - upper and lower and removed the lower steering bearing. I also installed the lower race. I'm having trouble with the upper race. The original upper bearing cup was not pressed in. It slipped right out. As I place the upper race in it also does not press in. I tapped with mallet and it appears to be all the way in, but not tight. See pics below. Also, see how much new race sets above the frame. It doesn't seem right. Please advise. Thanks, Sean
     

    Attached Files:

Share This Page