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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

    Hahaha! :laugh2: What I lack in skill, I make up for in being organized. It’s really the only way I can function.
     
    Hightower-Ash98, Jim, GLJ and 3 others like this.
  2. Mailman

    Mailman Hardly a Guru Top Contributor

    Well it’s just a few days short of a year since I got this old girl on the road, since then I’ve put a little over 2,000 miles on it and I’m very happy to say, it’s running like a top! Yesterday I had it out for a little highway action and when I got home I was looking it over and I noticed this.
    CF3D69B0-AF7A-4ADD-A511-CDA9C9C75B36.jpeg

    Thin little streaks of oil had blown back on my left side cover. I looked and couldn’t determine the source of it. There were no signs of an oil leak anywhere on the head or valve covers. I decided I would take a closer look today after the bike had cooled down over night. I finally found the source, coming from under the points cover.
    E68929C3-BBD8-4625-9BE0-95895A6D7FB6.jpeg

    I’ve got a cam seal weeping a little, it has from the very beginning. Usually I pop the cover off after every few rides and simply wipe up what has collected in the bottom, but I have forgotten about for a while and allowed it to pool up a little, then it seeps out from under the points cover and the wind was blowing it right back onto my side cover without ever dripping on the motor. The Pamco board is not oily, it dfrips down from the seal behind the plate and collects at the bottom.
    0D4C2AED-DD57-4E68-8352-731AF3FC5B64.jpeg

    The right side cam seal is dry as a bone. Someday I’m going to have to replace that seal, but for now it’s not really hard to keep up with. I just have to remember to clean in there. All buttoned up and ready to go.
    9FC8A9AD-BC0C-456B-859A-A83297B6B92B.jpeg

    Now a little update on my valve covers. The original XS2 valve covers used gaskets and were not machined for
    o-rings. A few months ago Gary very kindly took a set of old valve covers and machined some o-ring grooves in them and also sent me a set of his super duper red o-rings. I used to get a lot of seeping around the gaskets before, but now.....spotless. Thank you Gary!
    4D141A2C-ACFB-49B6-A0E1-5B6F5E44AE17.jpeg 1E06DA57-C9A8-460E-894B-827B714AB6A5.jpeg

    And lastly, yesterday when I gassed up my bike, I went to reset the odometer and the knob just spun in my fingers.
    The inside is stripped and will no longer turn the reset.
    56BBF1E2-555A-466B-A88D-AAADAAE3CE5B.jpeg 0D72DC08-25AE-43D8-87A6-3C98CA7CBCBB.jpeg

    Those knobs are impossible to find, they were never sold individually, they just came with the speedometer.
    I came across this on the HVCycle website. It’s billet aluminum and even though it’s marketed for RD350’s they say it may fit other models. I’m wandering if it’s worth taking the risk? It’s not cheap, it’s billet aluminum. It looks a little longer, but very similar.

    554A9E02-C466-4A76-AF11-C5386EEBAEDF.png

    Anyways thats all for now,
    Happy motoring- Bob :bike:
     
    TwoManyXS1Bs, Rasputin, GLJ and 2 others like this.
  3. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    I just do not understand why these camshaft end seals are such a PITA. There isn’t much oil in there and there is no pressure at all - just a bit of splash.
    Hmmm.....the next time I am inside one of these things I’m going to have to take a closer look.
     
    Mailman likes this.
  4. Jim

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

    You guys up for a little testing.... whistling_smiley small.jpg

    24x40x7mm seals.jpg
     
    MaxPete and GLJ like this.
  5. azman857

    azman857 '80 XS 650SG Rider XS650.com Supporter Top Contributor

    OOHHHH my my my....
     
  6. 2XSive

    2XSive At least one screw loose behind the handle bars XS650.com Supporter Top Contributor

    306
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    Michigan
    I rebuilt my 81 and was careful to center the camshaft knowing these seals are so sensitive. I have the same problem Mailman. I too have to clean the inside of the covers every couple hundred miles or else it weeps oil enough to blow all over my side covers just like on yours. Thinking the seals from Mikes just aren't up for the proper task. What's the "experiment" Jim? Are those seals something you sourced that are different than the ones from Mikes? I see they state "double lip". I'd be glad to order a set and give it a go....
     
    MaxPete, GLJ, Mailman and 1 other person like this.
  7. Mailman

    Mailman Hardly a Guru Top Contributor

    MaxPete and Jim like this.
  8. 2XSive

    2XSive At least one screw loose behind the handle bars XS650.com Supporter Top Contributor

    306
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    Michigan
    I even tried removing the gasket between the inner cover and head and just used a little permatex gasket sealer, thinking it would give me a little more real estate on the shaft for the seal lip to work better. Didn't work for me.
     
    Mailman and Jim like this.
  9. Jim

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

    Cam ends are 25mm in dia. Look again... whistling_smiley small.jpg
     
    MaxPete likes this.
  10. 2XSive

    2XSive At least one screw loose behind the handle bars XS650.com Supporter Top Contributor

    306
    1,230
    143
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    Ahh, everyone likes a tight seal, lol.
     
    MaxPete and Jim like this.
  11. Jim

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

    Left side of the SG motor's weeping too. Bought these to see if a slightly smaller seal will do the trick. Haven't swapped 'em yet, but I'm sure it will cure the problem. The testing is the longevity.
     
  12. arcticXS

    arcticXS XS650 Guru Top Contributor

    We
    Well, with TCI, Vape/Powerdynamo, or any other crank triggered ignition, the seals can be omitted altogether, and smaller "Shell" style cam end caps can be used. I got a pair from "Mule" myself, but Gary Hoos have them, and also Heiden Tuning: https://www.heidentuning.com/xs650-...-side-covers-aluminium-new-design-detail.html
     
    2XSive, MaxPete and Jim like this.
  13. Mailman

    Mailman Hardly a Guru Top Contributor

    Ahhh....now I see. I seem to remember you talking about these before.
     
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  14. Jim

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

    Yeah, I suggested them to RobinC. He never got to try 'em. :(
     
    gggGary, MaxPete and Mailman like this.
  15. Rasputin

    Rasputin XS650 Addict

    I wonder if a bearing with seals is available in that size. In the past I have used bearings with seals in similar situations. If so the bearing on the outside could be fitted with the outside seal left in and the inner seal removed, therefore adding an extra seal.
     
    JAX71224, gggGary, Jim and 2 others like this.
  16. 5twins

    5twins XS650 Guru Top Contributor

    19,263
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    These seals need to be very thin because there's not much cam sticking out. The originals are only 5mm thick so a 7mm one might be too thick. I think that's what the troublesome MikesXS seals are. They also market them as an improved version with a triple lip. But all the extra lips in the world will do no good if the seal's too thick and they don't make it onto the end of the camshaft.
     
  17. Ozboy

    Ozboy XS650 Addict

    Hey Mailman i would look into Speedi Sleeving that shaft. Exactly like mine. Right bone dry but left side kept leaking. I think they were 25.10mm sleeve with 40x25x5 seal. Mine been perfect for many years now.
     
    TwoManyXS1Bs, gggGary, Jim and 3 others like this.
  18. Mailman

    Mailman Hardly a Guru Top Contributor

    That sounds interesting, I’ll have to read up on that.
     
    arcticXS, gggGary and Jim like this.
  19. Ozboy

    Ozboy XS650 Addict

    Yeah 2000 miles is not alot so that was why i suggested it. You may be lucky the seal is damaged but the shaft maybe causing it. With mine no amount of scotch bright on the shaft and new seals could stop that damed thing leaking. A nice new interference fit stainless steel sealing surface is the go!
    Easy install for you and most local bearing places should have them or get them in for you....But it is metric tho:D:D..
     
    YamadudeXS650C, gggGary, Jim and 2 others like this.
  20. Rasputin

    Rasputin XS650 Addict

    Anyone know off the top what size the cam bearings are?
     
    Hightower-Ash98, Jim and gggGary like this.

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