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Mailman’s XS2 a full on restoration

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

  1. 59Tebo

    59Tebo 59Tebo Top Contributor

    Best of luck Bob! Hope everything makes the move in one piece and NO scratches! Take care of business and we'll catch up with you when you're settled...
    Jim, Mailman, MaxPete and 1 other person like this.
  2. mrtwowheel

    mrtwowheel Honda Etched On Brain Top Contributor

    When I moved from farm house to lake house, it took me just as long to move the garage as it did the rest of the house. I went from one huge garage/nice little barn, to one two car garage and one single car garage. Most of my tools, benches, cabinets went into the smaller garage. At first I put everything in there using the same layout that I had at the farm house, EXACTLY the same. Do this, you can make changes later, It's the only way it would have worked for me.

  3. kshansen

    kshansen XS650 Junkie Top Contributor

    Bob, Good luck on the move. We just finished helping some friends move out of there house. Problem is the deal on the house they were planning on moving into fell through AFTER they had signed the papers on their house!:wtf::banghead:

    Only good things are his mom has an upstairs they can use for now but nowhere enough room for even 1/4 of their stuff. The other sort of good thing is the place he works for has a 53 foot van trailer he can use for storage free of charge. Bad thing is they needed a place to "store" two cats and we got that honor!

    Hope you move goes smooth and you can get back to the `72 project soon. If I was closer I'd offer to help you move.
    TwoManyXS1Bs, Mailman and Jim like this.
  4. MaxPete

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

    Dangit Ken - I was just going to ask if you wanted to store two cats - permanently. They come with free litter boxes and food dishes.

    Any takers?
  5. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks guys, I appreciate the well wishes. I am busy packing my garage as we speak. My XS2 is now packed and I’m getting started on tools. Scott , I am going to try and replicate my workbench / pegboard as faithfully as possible. So much to do.
    I’ll keep you posted......
  6. MaxPete

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

    True....but also fun because you can make the OCD Workshop West - EVEN better than version v1 in Avondale.

    I'd be looking at:
    • air conditioning (you DO live in a place that is much like the surface of the sun);
    • improved lighting (you're not getting any younger ol' buddy);
    • some amenities such as a BEvERages fridge, one of those snazzy LED light / bluetooth speaker combos and perhaps a big-@ss TV (for those loooong evenings of endless cleaning and polishing...);
    • some decent chair(s) (who knows, a friend or two might drop-by - maybe with their new young son, or perhaps even from a far-off foreign land.....);
    • etc., etc.
    You've spent the big coin - now is the time to stretch a little further and really go for it! ;)
    TwoManyXS1Bs, Jim and robinc like this.
  7. Mailman

    Mailman Hardly a Guru Top Contributor

    Pete, I like the way you think! You don’t have to sell me on all that stuff......think you could swing by and convince my wife? Maybe a little something like this?
  8. robinc

    robinc Member of the 'yellow meter gang' Top Contributor

    Looks like a good start Bob.
    Jim, kshansen and Mailman like this.
  9. MaxPete

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

    Sure Bob - I’ll swing by right after Dude suggests the Kitchen Engine Rebuilding Shop idea to her.....:yikes:

    Then we can retreat to my place until things calm down....:D
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    Well!! AFTER ONLY 60 days out of commission,

    Before I was SO rudely interrupted, I was in a hurry to get my engine ready to move, so things were not really buttoned up, I just threw covers back on and called it good to go. The advance rod, points, oil filters, cam chain adjuster, misc gaskets are all yet to be installed.

    Today I finally had some free time and got started again , YAY! I pulled off my compression release/ exhaust valve cover to replace the seal in there.
    DB3FC9B9-8FF3-4A25-A203-8B03C991F3B2.jpeg 8A3C5365-A657-4C6B-8B92-F912E994560B.jpeg

    Out with the old,

    And press the new seal into place.

    Then reassemble the decompression assembly.
    EC72088F-7A40-42C8-A930-6D493FE3E001.jpeg 6A5AD778-0BD2-43DC-BD79-8B9DA3BA1795.jpeg

    And for now, I’m just going to put it back in place without the gasket. I still need to adjust the valves.

    From there, I moved on to the cam chain adjuster. I had considered polishing this, but decided to paint it like the case.

    New gasket with a thin schmear of Hylomar,
    7C3BC7B6-EFF0-490A-8734-FEB1F832D07A.jpeg 45D1479C-EF38-4637-B509-4EB29AE7368C.jpeg 10F36124-FD24-4AB7-B119-BF5B9BB1A918.jpeg
    A drop of blue locktight on the threads 86A9D234-B52E-46E2-AC54-48EDCB421CCF.jpeg

    Install the cam chain adjuster,

    A new cork gasket, and it’s all together.

    I measure progress by empty containers, so two down!

    Now I’m interested in some opinions here, just curious what you guys think. I still need to install the gaskets and o rings behind the cam seal covers. The cam seals seem to cause a lot of guys trouble, the seals just barely have enough room to cover the end of the camshaft. Now there is a gasket and an oring behind the cover.

    And the oring fits into this machined recess in the head.

    So I’m thinking that the oring will flatten out in that machined space and won’t add too much to the thickness.
    What I’m wondering is, I’ve heard of some guys with chronically leaking seals, remove the gasket and just put some gasket sealer behind the housing.
    How common is that for those seals to leak, what have some of you done to try and fix it, and is it advisable to leave either the oring or gaskets out? Just curious. Thanks!
    See you again soon, I’m Back!
  11. robinc

    robinc Member of the 'yellow meter gang' Top Contributor

    Ahhhhhh, nice to see that things have settled down and returned to normal. Bob's back, back in the shop again. I'll sleep better tonight.

    Lookin' good Bob!
  12. Jim

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

    Honestly, I've never understood Yamaha's logic in using a gasket and O-ring both on those end caps. My opinion, it wouldn't hurt a thing to just go with the O-rings. I do know from measuring my XS1 engine, that without the gaskets, there will be no discernible clearance across the cam and bearings. In other words, that's as far in as the end caps will go. Best chance ya got for the garlock seals not leakin....
    Also, didn't see any blue locktite on the decompress shaft bolt. I'd suggest some. Don't want that thing rattling around inside the rocker box. :yikes:
  13. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Robin! It felt good to back to working on my old bike again!
    robinc likes this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    Haha! I just didn’t photograph it, I put locktight on the set bolt threads.

    So you’re saying you wouldn’t have any qualms using just the orings and leaving out the gaskets?
    MaxPete likes this.
  15. Jim

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

    Correct. The three screw holes to attach the cap don't go all the way through to the inside of the head... so there's really no need for the gasket. Just the O-ring should work just fine.
    MaxPete, robinc and Mailman like this.
  16. Mailman

    Mailman Hardly a Guru Top Contributor

    Gotcha! I’ve been thinking about doing that. I might just give that a try.
    Thanks Jim!
    MaxPete and Jim like this.
  17. Jim

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

    He can pipe in here and correct me if I'm wrong, but I think Robin eventually went without the gaskets.... Robin?
    robinc likes this.
  18. Jim

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

    Oh... and make sure the head fasteners are just lightly snugged. They need to be loose so the caps can move the cam bearings to center them. Otherwise the caps won't draw up flush.
    robinc likes this.
  19. Mailman

    Mailman Hardly a Guru Top Contributor

    Before I put my engine into hibernation, I installed the caps and valve covers, made sure everything was located in place and lightly snugged, then torqued the head down to about two thirds of its eventual value just to seal the rocker cover and center the bearings.
    I intend to finish torqueing the head after the motor is installed.
    robinc and Jim like this.
  20. Oddjob

    Oddjob adsgads

    Hi Mailman... very nice...

    Curious about the compression lever assembly... is the only difference the cover/lever assembly, or does it require a specific rocker arm (or head perhaps) in order to function?
    Jim likes this.

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