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Mailman’s XS2 a full on restoration
- Thread starter Mailman
- Start date
Good idea, i only run AGM nowdays. I dont know why they sell the liquid ones anymore. With all the acid attacks over in the UK im sure there will be restrictions at some point.
yellowdog
yellowdog
On mine the only parts I had powder coated were the air filter covers and the battery tray.
From what I remember the only parts I could never find were the small rubber absorbers that go in the front brake assembly ,I made my own using something called sugru.
Curious about the comment about acid attacks ,are they a uk thing only,absolutely cowardly thing to do .
From what I remember the only parts I could never find were the small rubber absorbers that go in the front brake assembly ,I made my own using something called sugru.
Curious about the comment about acid attacks ,are they a uk thing only,absolutely cowardly thing to do .
Thanks for the tip on sugru. I’ll have to look into that.
Hello Bob
Just noticed this thread. Can't tell you how excited I am by the prospect of being entertained and informed by another of your meticulous restorations. That is a lovely motorcycle. The XS2 is a crowd pleaser and this one has had the good fortune to fall into capable and caring hands. I can already imagine what she'll look like in a couple of months and I predict a calendar job in the making.
You could, of course, gone fishing, wrote your memoirs, taken up Bonsai or simply enjoyed the '77 but, if you must suffer from some form of OCD at least you have chosen a worthwhile compulsion.
Bon chance mon ami!
Just noticed this thread. Can't tell you how excited I am by the prospect of being entertained and informed by another of your meticulous restorations. That is a lovely motorcycle. The XS2 is a crowd pleaser and this one has had the good fortune to fall into capable and caring hands. I can already imagine what she'll look like in a couple of months and I predict a calendar job in the making.
You could, of course, gone fishing, wrote your memoirs, taken up Bonsai or simply enjoyed the '77 but, if you must suffer from some form of OCD at least you have chosen a worthwhile compulsion.
Bon chance mon ami!
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Haha! David you're my biggest fan! It really is a sickness isn't it? What normal person would think he won the lottery by scoring some rusty heap, that's going to cause heartache, busted knuckles and a detour into my retirement savings? And then just when you think you've got all the ailments knocked down, along comes the next challenge! Stay tuned my friend, and by the way, when are we going to see some photos of your lovely bike?
I just noticed you are from the Uk. I have seen quite a few reports on BBC of people that have been burned badly over there. I haven't heard of any acid attacks over here but as you know we have other problems. Also by very cowardly people.
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Ok, I reluctantly had to take a break from my little project to catch up on my honey do’s.
So back to more first impression photos, in no special order.
The front disc doesn’t look bad, I grabbed it and tried to wiggle it to see if I could detect any play, no wiggle, don’t know if that means anything or not yet.
Front forks are weeping and feel like they have no oil in them.
A couple views of the header pipes. The left one is more blues than the right. Has it been running too lean? It’s been a while since I’ve had a bike that had un synced carburetors. Im going to have to learn new tuning rituals.
Alternator windings look good, nice color, not burned. This bike was throwing a good charge. I tested it with my meter when the owner fired it up. You could’ve knocked me over with a feather.
Also no sign of oil in the alternator housing, YAY!
A couple underside photos.
Pulled the left cover off. I kinda felt like maybe I was the first one to remove it since it left the factory. Only 5500 miles on the bike, and still, it looks like I might be replacing the clutch pushrod seal.
Checkout the old ( empty) Black Widow egg sack. It’s still there I haven’t touched anything yet.
On my ‘77 the oil breather hoses are routed back into the air box, but on this bike they are just routed down behind the motor, where they belch oil fumes all over the frame and underside.
The above photo also shows the rusted center stand, a victim of battery acid im afraid, as well as the lower frame in the left side.
Some more motor shots.
All the valve tappet inspection covers were pushing out a lot of oil. The underside of the gas tank had a lot of oil from vapor on it. I’ve got my work cut out for me trying to remove stains from the paint on the gas tank.
Here , I don’t know if you can see it well, up under the steering head there is a bunch of grass and string and junk packed in there, I think a mouse was making it home.
The battery box rubber insulator is shot, may have to get creative there, doubt I’ll find a replacement.
That’s all I’ve got for now, I’ll post some more as soon as I can.
I sure am having fun!
So back to more first impression photos, in no special order.
The front disc doesn’t look bad, I grabbed it and tried to wiggle it to see if I could detect any play, no wiggle, don’t know if that means anything or not yet.
Front forks are weeping and feel like they have no oil in them.
A couple views of the header pipes. The left one is more blues than the right. Has it been running too lean? It’s been a while since I’ve had a bike that had un synced carburetors. Im going to have to learn new tuning rituals.
Alternator windings look good, nice color, not burned. This bike was throwing a good charge. I tested it with my meter when the owner fired it up. You could’ve knocked me over with a feather.
Also no sign of oil in the alternator housing, YAY!
A couple underside photos.
Pulled the left cover off. I kinda felt like maybe I was the first one to remove it since it left the factory. Only 5500 miles on the bike, and still, it looks like I might be replacing the clutch pushrod seal.
Checkout the old ( empty) Black Widow egg sack. It’s still there I haven’t touched anything yet.
On my ‘77 the oil breather hoses are routed back into the air box, but on this bike they are just routed down behind the motor, where they belch oil fumes all over the frame and underside.
The above photo also shows the rusted center stand, a victim of battery acid im afraid, as well as the lower frame in the left side.
Some more motor shots.
All the valve tappet inspection covers were pushing out a lot of oil. The underside of the gas tank had a lot of oil from vapor on it. I’ve got my work cut out for me trying to remove stains from the paint on the gas tank.
Here , I don’t know if you can see it well, up under the steering head there is a bunch of grass and string and junk packed in there, I think a mouse was making it home.
The battery box rubber insulator is shot, may have to get creative there, doubt I’ll find a replacement.
That’s all I’ve got for now, I’ll post some more as soon as I can.
I sure am having fun!
Wow, great pics Bob. You are documenting this like there's no tomorrow. Nicely done. A true Mailman job! Thanks for taking us along for the ride buddy!
Ha! Thanks Robin, I wasn't sure if anyone else would find this stuff interesting, to me the fact that this bike was hiding in the corner of a garage for 36 years and I get the opportunity to revive it is pretty cool. I've never done anything quite like this and I'm taking my time with it.
It looks pretty solid to me Bob - no showstoppers that I can see.
Pete
Pete
Are you kidding?!?! We're gearheads... remember? Keep em coming Bob.
Hey Bob, 3rd pic down. Looks like the tank is touching the head bolts. You might be missing some tank rubbers....
Good eye Jim!
So as I said, the guy I bought the bike from was not a bike guy. He did a quick and dirty clean up just to get the bike started. After I bought the bike he says, "Oh I have some spare parts, I'll go get them." He comes back with a plastic bag and in the bag are the tank mounting rubbers. I pointed that out to him and he goes, oh that explains why the tank rattles so much when I start it up!" The tank is going to be a challenge for me. I really want to preserve the original finish, but it's going to take a lot of work.
The loom looks real good. Still has the Yamaha coating on the tappet covers.
What is your end game on this Bob. The reason i ask is i see a bike that needs a good clean polish, as is, and the bike will be at its best value and visually look great and the cost is kept to a minimum. Maybe the engine may need some work and that is where the money will go, and you could still be in the ball park to have a investment with no debit on paper and may well be in the credit. ...............Not that i think it would be for sale
Of course the usual things to do as per a sitting bike, loom continuity and connections, (bet the loom and connections are good), general testing bla bla as per 77. But on this bike a good clean rub and a quick polish on the chrome and engine covers, (no grit), and the bike will be a 5 footer.
What is your end game on this Bob. The reason i ask is i see a bike that needs a good clean polish, as is, and the bike will be at its best value and visually look great and the cost is kept to a minimum. Maybe the engine may need some work and that is where the money will go, and you could still be in the ball park to have a investment with no debit on paper and may well be in the credit. ...............Not that i think it would be for sale
Of course the usual things to do as per a sitting bike, loom continuity and connections, (bet the loom and connections are good), general testing bla bla as per 77. But on this bike a good clean rub and a quick polish on the chrome and engine covers, (no grit), and the bike will be a 5 footer.
My God she's in great shape Bob! What's an X2? 1972 or thereabouts? I was 17 and almost a virgin, (almost!). Now I'm 63 and almost incapable! Your bike looks a damn site better than I did at 46. Hardly a challenge to a man of your talents. Just evict the rat and add another month to my earlier prediction.
Agreed - I’d mixup a good bucket of warm water and dish soap and get a scrub brush going on it. I’ll bet it will look even better. Renew the rubber bits and cables....and you'll have yourself a ballgame!
That IS my plan Skull. I really want to keep it original and just make it mechanically sound and rideable.
Thanks David,
Yes, an XS2 is generally considered to be a ‘72, although my bike was manufactured in ‘71 and is titled as such.
Great pics, Bob. Let's us scrutinize. Aside from the vintage filth, and Jim's mention of the tank/head contact, all I can see out of order is a possibly degraded plug wire. If it's from mouse chewing, closely examine all the wiring. Those guys go after the salt taste in the insulation...
