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Mailman’s XS2 a full on restoration

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

  1. Jim

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

    ..... or a couple of very big ones.

    FB71, MaxPete and geedubya like this.
  2. Mailman

    Mailman Hardly a Guru Top Contributor

    Ha! That’s pretty cool!
    Jim likes this.
  3. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Bob, hope you don't think we're pickin' on ya. But, here's another.

    Front brake stay retainer bolt.

    That's a really nice, clean pic of the backside of your rear brake actuator. Saved a copy for my files.

    Item 1 - Your pic clearly shows the ideal movement zone of the pivot arm's clevis, just below and as close to the swingarm pivot as possible. That'll minimize the effects of suspension movements on the braking geometry.


    Now, item 2 - note the orientation of the brake stay bolt, #36, in this parts pic.


    And, note the orientation of that same bolt on my skungy XS1B.


    I believe that the bolt's thin/flat head is meant to provide clearance for the brake rod. Check yours to see if the bolt's protruding threads scrape on the brake rod...
    Last edited: Jan 28, 2019
  4. Mailman

    Mailman Hardly a Guru Top Contributor

    Wow 2M! That’s a good catch! I’ll take a look at it today and likely reverse it. Not picking on me at all! I would’ve missed that detail.
    Thanks buddy! :thumbsup:
  5. Mailman

    Mailman Hardly a Guru Top Contributor


    The headlight shell , front turn signals , and rear brake light switch.

    Before I got started I wanted to check that potential clearance issue that 2M spotted with my front brake stay bolt being inserted backward. He was concerned that it might interfere with the brake control rod. It turns out there was enough clearance, less than if I had the bolt in the other way around but still ok, so I’m gonna leave it alone.

    Then I unpacked my headlight shell and installed new rubber grommets in the back and the high beam indicator lens in the top and also the square hole grommets In the side of the shell.
    75509179-3F04-4AD5-8ED7-C83F3D412992.jpeg F7B1B0E8-3C0E-4CD0-B4DC-E1E5A9E647B9.jpeg 56D7F402-50D3-43A1-87F7-ADBB7AFC7535.jpeg
    The fresh paint was thick and I had to trim the inside of the mounting hole with an Xacto knife to obtain clearance.
    I also had to run a tap through the threaded mounting hole on the bottom of the shell.
    F41927C2-D516-4083-97BF-75E043DE2819.jpeg C84A03B2-0829-43EB-AF2A-30517A1F48DE.jpeg

    Then I installed the rubber grommets in the headlight ears and mounted the shell up. I also relocated the turn signals to the side of the headlight instead of mounting them on top of the forks the way the factory did.
    E13DCCD1-08C3-4793-B6C8-59F946DC3F54.jpeg 1532BF7A-17AB-4DD8-A875-9EE27F99100B.jpeg

    I hadn’t even looked at the turn signals prior to this moment. I just had them stashed in a tub. I realized that one lens had a bad scuff on it and they were just rather dull in appearance.....and that’ll never do!

    So they got the headlight restoration polish treatment. Now I can’t even tell which one was scuffed.
    5A2B3772-8B23-40A2-AAA1-5689B004B0AB.jpeg 6D919B3C-B9CD-433D-8D7C-328D44C47095.jpeg DA518EEB-4843-4EFD-8A6D-FAD14782A713.jpeg

    Much better! Now onto installing my rear brake light switch.

    The first thing I did was clean up the terminal ends with a Dremel and check it’s operation with with a multi meter,
    It only needs about 4-5 mm travel to operate the switch, alls good.

    I installed the switch , adjusted the free play and tested it again with the multi meter, this time by depressing the brake pedal and Bingo! It’s a go.

    I’m racking up a lot of empty containers and that doesn’t tell half the story, I had big storage tubs full of large components, painted swingarm, side stand battery box, all sorts of mounting hardware and large components such as front and rear fenders......I’m gaining momentum now.
    BEBA7B43-EB83-462C-8C53-9EFEACCD79FC.jpeg FDDF5DEC-4254-4DCC-B519-DF28959C6EF4.jpeg

    Bob :thumbsup:
    madmax-im, Meddy, 59Tebo and 8 others like this.
  6. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    :cheers: Looking fanF$%^&tastic!
    TwoManyXS1Bs, gggGary and Jim like this.
  7. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks buddy! :bike:
    GLJ likes this.
  8. Jim

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

    You're on a tear now buddy. :D
  9. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    TwoManyXS1Bs and Jim like this.
  10. Mailman

    Mailman Hardly a Guru Top Contributor

    Please don’t let anything I do influence your decisions. I like what you’re doing and enjoy reading about it, as I’m sure others do. The beauty of this forum is everybody doin their own thing. There is no one way that’s better.
    I freely admit I got carried away on this bike , for me it’s kind of a bucket list thing. I’ll probably never do a nut and bolt restoration again. Going foward, anything I do would be much more in line with what you’re doing. So please keep it up.

    As for that link.....I’ve already been there and downloaded all those photos for reference. Haha!
  11. YamadudeXS650C

    YamadudeXS650C Central New York XS650 XS650.com Supporter Top Contributor

    Looks great, Bob, like a museum piece !
    I'm seeing a spot at the Guggenheim for it.

  12. Mailman

    Mailman Hardly a Guru Top Contributor

    Yeah, I’m on a roll now. That’s usually when the wheels come off! Haha!
  13. Mailman

    Mailman Hardly a Guru Top Contributor

    Or in your living room next to your Triumph! :D
    geedubya, TwoManyXS1Bs, Jim and 2 others like this.
  14. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Yer Make'n my hands sweat Bob!
    madmax-im, Machine, geedubya and 3 others like this.
  15. Mailman

    Mailman Hardly a Guru Top Contributor

    I’m waiting with baited breath to see what you’ve got up you sleeve, my brother! That is if you don’t get Buell fever this spring!
  16. Jim

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

    Too late..... :rolleyes:
    gggGary and Mailman like this.
  17. cra-z1

    cra-z1 XS650 Junkie

    Its looking good. Wait till you get it on the road. You will get the looks, thumbs up, questions and smiles from a lot of people. I had some guy come up to me when I had one of my Z1 bikes out and tell me he got a woodie(because of the bike not me) when I pulled in. I hope you dont get that kind of attention
  18. DoubleE

    DoubleE XS650 Enthusiast

    Ohio USA
    I put on my sunglasses on every time I click on this link. "Futures so bright, ya gotta wear shades" Looking great.
  19. Mailman

    Mailman Hardly a Guru Top Contributor

    Haha! Thanks guys, I sure hope it runs! :laugh2:
    Machine, TwoManyXS1Bs and Jim like this.
  20. MaxPete

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

    Looking great Bob!

    TwoManyXS1Bs, Jim and Mailman like this.

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