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Mailmans , 77D getting a makeover

Discussion in 'The Garage' started by Mailman, May 5, 2019.

  1. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Don't forget Lowes and Home Depot. They usually have a selection also.
    Mailman likes this.
  2. Mailman

    Mailman Hardly a Guru Top Contributor

    Yeah, I will. I forgot you asked about the OD of that sleeve. I’m not sure right now, I’d have to measure it.
    Jim likes this.
  3. willis

    willis XS650 Junkie XS650.com Supporter

    Bob, I’ve got a nice extra set you can have that I just took off my 75. Payback for the master cylinder rebuild kit you sent me. Pm me your address again and I’ll chuck them in the mail for ya. Pretty sure I’ve got a couple extra set so it’s no big deal. I recently installed some of the aluminum knob kits that are being sold in the classifieds right now.
    TwoManyXS1Bs, Jim and Mailman like this.
  4. Mailman

    Mailman Hardly a Guru Top Contributor

    Willis, that’s very generous of you. The knobs I have are ok, it’s the rubber grommets with the metal inner sleeves that I’m having to find. If you have the rubber parts, I’d be interested.
    By the way, those custom aluminum knobs you just got are killer!
    Jim likes this.
  5. willis

    willis XS650 Junkie XS650.com Supporter

    I’ll have a look in the morning and report back
    Mailman, Jim and mrtwowheel like this.
  6. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Try your rubber softening trick on it?
    Jim likes this.
  7. willis

    willis XS650 Junkie XS650.com Supporter

    Bob, I do have a pair you can have. They aren’t perfect but very usable. Measure 14mm on inner mounting surface. Also I checked Partzilla and they show available for under $3 each. Part # 90480-14024-00 Grommet. Let me know and I’ll throw them in an envelope and get them headed your way if you want them.
  8. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Willis!
    PM sent.
    gggGary and Jim like this.
  9. Mailman

    Mailman Hardly a Guru Top Contributor


    110 degrees today, the first of very many to come here in the desert. Our summers are ( in a way) like the freezing winters back East, in that all you wanna do is stay inside. Ah....but it’s a dry heat, as they say.

    So...where was I before the Mrs. side tracked me with a bathroom painting project?

    Ah yes! Gary’s super duper red silicone o-rings arrived a couple days ago, thank you Gary! You can see how nice and thick they are , side by side with the old ones.
    But I couldn’t stick these nice new o rings in those dirty old valve covers! They still had clear coat on them, that had seen better days.

    So I hot tanked them in my ultrasonic cleaner for about 30 minutes and the clear coat slid right off. Then I hit them on the buffer and then blue magic. Ahhh.....much better! My bike looks faster already!

    O rings lightly coated with silicone grease and installed in the valve covers.

    Then mounted those puppy’s up, being careful to follow Gary’s recommendation that they not be tightened down too hard. Yeah, that’s the ticket!
    860A93B0-C085-4B26-83D8-CDC654DA18D2.jpeg 3FF7AC99-7993-4CB9-9F00-41EC3554435D.jpeg

    I finished up the day by installing my hipster hand grips! Using my favorite adhesive.
    218956CE-56EA-4BED-B6FB-649BDE613F10.jpeg 0A138EA3-82B2-4E3F-8E07-BD0BAEFF3E05.jpeg

    That’s enough for today, my garage is heating up!
  10. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Getting closer.
    In 10...9....8....

  11. Mailman

    Mailman Hardly a Guru Top Contributor

    Yeah buddy! After I get the tank back on, I still need to go through the tune up rituals. I have been undecided about what to do with those beautiful black side covers you painted for me. I have already bought gold pinstripe tape and XS650 decals. But I don’t know. I may just stick them on unadorned for a while and see how it strikes me.
    Might just take a simplistic approach.
    Last edited: Jun 12, 2019 at 6:02 PM
  12. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    I like that idea.:smoke:
    MaxPete, gggGary and Mailman like this.
  13. willis

    willis XS650 Junkie XS650.com Supporter

    I like the grips. I think they will compliment your tank decals nice.
    MaxPete, gggGary and Jim like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks! I think they go together nicely too!
  15. geedubya

    geedubya geedubya Top Contributor XS650.com Supporter

    B-O-B,I see you use only good Ozzie hair spray perhaps, it may have helped you earlier in more top of the skull pursuit.


    Jim, Mailman and gggGary like this.
  16. Mailman

    Mailman Hardly a Guru Top Contributor

    Well today, I am pretty much winding up my make over thread. Today I started by applying my new Yamaha roundels to my gas tank and then installing my tank, and cutting my fuel lines to length and getting everything hooked up.

    I’ve got my battery out and on the bench, where I cleaned up the terminals and now have it on the charger.

    I installed my recovered seat.

    And then the mailman showed up, perfect timing! Earlier this week , Willis sent me a couple of side cover grommets , to replace my rotted ones. They cleaned up beautifully and I installed them in my side covers, and put the side covers on my bike.
    384A2CA5-1B7F-47B1-8E6F-E83586810F53.jpeg B36A9E08-27EB-4ACF-A3D7-E1766DE73946.jpeg

    There are still some things to be done, there’s no gas in the tank, and I need to get my bike started and throw my manometer on the carbies and balance them, but nothing much to write about there.
    Maybe after I get it running , I’ll post a little video of it running.
    Until then, I’m going to call this makeover complete!

    F4B66125-7F93-4942-8370-6077084A21FA.jpeg I’d like to give a shout out to Jim, for doing such a nice job painting my side covers,
    He is a total pro to deal with, always prompt and professional!
    Also to Willis for hooking me up with those side cover grommets, he really got them to me fast and I appreciate it!
    You guys rock!
    0C2DF409-E23A-47EB-B0EB-B89C3E6CE1F3.jpeg 5C5D1118-15CA-42E4-8630-B4F8F01186E0.jpeg B0AB33E9-3CF2-4ECA-B8E2-AB1AE5C185AD.jpeg 0B0DADC0-0781-4AD3-AAA1-87A2EEA1959B.jpeg

    “Did you ever have to finally decide? To pick up on one and leave the other behind?”


    The Lovin’ Spoonful , Make up your mind

  17. willis

    willis XS650 Junkie XS650.com Supporter

    What a pair Bob! Both are looking SUPERB. Is your wife starting to wonder "WHAT'S NEXT?" yet ?
  18. Jim

    Jim The thrill of victory and da agony of da feet. Top Contributor XS650.com Supporter

    Damn fine lookin' stablemates there Bob!!
    Love the Bonnie look of the 'D' :D
    MrBultaco, Machine and Mailman like this.
  19. Mailman

    Mailman Hardly a Guru Top Contributor

    Thanks Willis! I think I need to let my credit card cool off for a while , if you know what I mean, it’s still smokin! :D

    Thanks Jim! I’ve gotta say, I’m really liking the clean look of it overall. I’m a little surprised by that. It does look a little Bonneville like , doesn’t it?

    The before and after......;)
  20. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    Looks great. I do think it could use a little color on the side covers. Maybe a small gold pinstripe.

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