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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

    Sean, here you go.

    The ball bearing races fit down flush with the steering neck, the tapered races are taller and stick up above the neck a little. It’s fine. It doesn’t hurt a thing. Here you can see how much mine extends above the top.
    6F195EFD-B1B8-4FD4-B850-F1FAD08105A2.jpeg

    As for the looseness, I ran into that exact issue, here, read this post all the way through. It covers how I addressed it. Post #1720. P.S. disregard the zerk fitting, that was a mistake.
    http://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-86#post-576489
     
    TwoManyXS1Bs and YamadudeXS650C like this.
  2. Norton7d

    Norton7d XS650 Junkie

    Scanney, did u take any pics or measurements of the old race(s) prior to removal, if not, you have now learned the value of documenting changes, especially those during the "unsuccessful" phase.
     
  3. scanney

    scanney XS650 Enthusiast

    I did. The old race or cup is 7 mm high and the new one is 11 mm.
     
  4. Norton7d

    Norton7d XS650 Junkie

    Did you confirm:
    Old race is down in the neck as far as it can go before hitting the seat?
     
  5. scanney

    scanney XS650 Enthusiast

    Yep
     
  6. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi azman,
    that was when the Brits Decimalized the money. Typical eff-up.
    The details are too complicated to describe here but here's one example:-
    Buddy was a 'bus conductor on Decimal-Day morning.
    They gave him a "float" of new coinage and he scrolled tickets and made change by guesswork until shift end. Nobody complained
    The "float" and the ticket scroller money count get handed in. Any shortfall gets taken from your wages.
    He had so much extra money that he split it with his driver.
     
    MaxPete and gggGary like this.
  7. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Sean,
    Stick 'em in with Loctite bearing retention compound.
    It ain't a bodge, it's an upgrade.
    I had a small part in pioneering the technique on aircraft landing gear back in the 1950s
    Back then there was just plain ol' Loctite thread locking compound and I reckon Loctite
    owes us bigtime.
     
    Jim, MaxPete, gggGary and 2 others like this.
  8. scanney

    scanney XS650 Enthusiast

    Thanks Fred!
     
    Jim and MaxPete like this.
  9. scanney

    scanney XS650 Enthusiast

    And thanks for the "clamp" idea. I replicated your clamp with parts from Ace Hardware. Sean
     
    Jim and MaxPete like this.
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    You’re welcome. That same piece of all thread and the large flat washers, was also used for installing new bronze swingarm bushings. So hang onto it, you’ll probably use it again!
     
    gggGary, 59Tebo, scanney and 2 others like this.
  11. scanney

    scanney XS650 Enthusiast

    Hey Bob, another related question or two. I am attempting to remove the inner dampening rod in the lower fork. The allen bolt of course turns without loosening. I don't an impact wrench. Is there a bolt or nut on the other end of the rod (tube side) that I can reach with a ratchet extension? If so, what is the size of the bolt or nut? If I can tie in to that and hold one end while I turn the other I should be good. Thanks again, Sean
     
  12. Mailman

    Mailman Hardly a Guru Top Contributor

    Yes, post number #1425 shows how this is done.
    http://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-72#post-572750

    I simply took an old cheapo 13mm socket and took a hacksaw to it. Cut it so that the socket has two flat sides to hold that damper inside the leg. Then attach it to a couple long extensions. It’s all shown in the post. Good luck!
    11CB689B-FB00-4985-9E22-4121DE0554B7.jpeg
     
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  13. scanney

    scanney XS650 Enthusiast

    Hey Bob, thanks you got me moving again. I'll get after and old 13 mm socket later today and proceed as indicated. I really appreciate your quick and thorough advice. Sean
     
    gggGary and YamadudeXS650C like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    You’re welcome! :thumbsup:
     
    gggGary and Jim like this.
  15. 59Tebo

    59Tebo 59Tebo Top Contributor

    Yeah, Bob, I think I might have one or two of those sockets floating around... Might even be worth it to scare up some 3/8" square stock (to make a proper length extension, that won't come apart, 'cuz the sockets are welded on), and build a dedicated tool just for this purpose. Since it looks like a snow globe outside, maybe (between naps and football games) I'll scrounge around and see what I can find... :shrug:
     
  16. I congratulate you for a beautiful build. And thank you for a most excellent build thread. This thread should be read by anyone thinking about a restoration.
    Again thanks.
    john
     
    TwoManyXS1Bs, gggGary and Jim like this.
  17. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks John! I appreciate that. Did you actually read the whole thing? :laugh2:
    I really enjoyed the whole process, and I learned a whole bunch along the way.
     
    TwoManyXS1Bs, 59Tebo and gggGary like this.
  18. Pretty much, only miner brain glazing
    john
     
    TwoManyXS1Bs, 59Tebo and Mailman like this.
  19. scanney

    scanney XS650 Enthusiast

    Me again. The steering head bearings are in! All looks good. Thank you. Now my next dilemma, I was able to remove the allen bolt from the bottom of the fork using your special 13 mm socket tool. Thanks again. However I am now wrestling with removal of the fork seals. I bought the special tool on sale at NAPA. My first attempt was unsuccessful. I have read a number of comments in the forum and will try other approaches. Do you have suggestions? Thanks, Sean
     
  20. willis

    willis xsive compulsive disorder XS650.com Supporter Top Contributor

    I recently removed the seals from a set of '75 lowers. I used Gary's method of clamping a tire spoon in the vice and leveraging the lower on the fixed spoon. I was also very careful about not prying directly on the face of the lower, as the PO had done that and damaged the aluminum. Which is why i was replacing the lowers in the first place. I used a very thick piece of cardboard in between the spoon and lower as a cushion.

    http://www.xs650.com/threads/fork-seal-bearing-puller.48379/#post-490096
     
    YamadudeXS650C likes this.

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