PHANTOM RESURRECTION 78 SPECIAL

[The Phantom]

Hey! I was too embarrassed to admit I dropped the bloody popsicle stick into the case as I was mounting the jugs. Luckily it fell out during the oil change.
Please take a look at the case pics. Strange looking metal looks like a repair. Any ideas? Looks suspicious. The “ cracks “ as well. Thanks

 

[YamadudeXS650C]

Hey! I was too embarrassed to admit I dropped the bloody popsicle stick into the case as I was mounting the jugs. Luckily it fell out during the oil change.
Please take a look at the case pics. Strange looking metal looks like a repair. Any ideas? Looks suspicious. The “ cracks “ as well. Thanks
View attachment 255465

Looks to me like Hi Heat or Extreme Heat JB Weld, but not sure what the PO was up to.

The "cracks" look like typical casting marks, nothing to worry about.



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[Jim]

Not a repair. When the factory drilled out the oil passages, they'd swage a metal ball in the opening and cover that over with some sort of epoxy. In other words, the "patches" are normal.

....and as Jeff said, those likely aren't cracks. They're casting marks.... normal again.

 

[The Phantom]

Not a repair. When the factory drilled out the oil passages, they'd swage a metal ball in the opening and cover that over with some sort of epoxy. In other words, the "patches" are normal.

....and as Jeff said, those likely aren't cracks. They're casting marks.... normal again.

I just figured I’d bring it to your attention. Thanks so much. It’s great to have this resource. I doubt the manuals would have this specific type of info that usually comes from years of work

 

[The Phantom]

So, I bought this new (to me) sx650 from an outstanding junkyard in Madison Co. Va. It was obvious it had been laid down on both sides. But, the engine had oil and the kickstart moved as well as the gears changed. The junkyard owner had recently pulled it out of storage for 38 years, and wanted a nominal sum. I resurrected an 81 CAMARO from his junkyard during Covid so he likes me,, a lot. He knew nothing other than the storage period. Now it’s in my back yard. Engine is covered on my back porch after recent removal. It is a 78 Special with matching frame and engine VIN.
I’m doing this for my 22 year old as I refused to get him a motorcycle when he was a teenager. I haven’t ridden since 85.
Thanks to Jim for getting this started. I’m looking forward to this experience with you all!

Hi fellas, I’m interested in cleaning/ checking out the oil pump before I start this bad boy for the first time. In removing the cover, do I need to drain the oil change I already did? I know, stupid question but videos I’ve watched do not specify this possible step. Thanks

 

[The Phantom]

To the best of my knowledge these are from my '78 Special.
You'll need a couple of securing pins (or such) at the base. You could get creative with the method of securing, like small bolts.
You can have them for the price of shipping, maybe 10 bucks or so.
I'm just north of you near Syracuse NY.
Send me your zip in a PM (22936?) and I can be more accurate on the ship cost.

Jeff

View attachment 251990

Hi, I’m ready to rebuild the brakes. Do you have any suggestions about where to get front and rear caliper rebuild kits as well as front and rear new hoses. Also rebuild kits for front and rear master cylinders? I’d appreciate it muchly

 

[jetmechmarty]

Hi, I’m ready to rebuild the brakes. Do you have any suggestions about where to get front and rear caliper rebuild kits as well as front and rear new hoses. Also rebuild kits for front and rear master cylinders? I’d appreciate it muchly

https://www.georgefixs.com/

Fast responder. K&L kits.

 

[Wingedwheel]

I bought one of these for the front and they work and fit quite well. You’ll need a 10mm/AN3 adapter for the caliper but those are easily sourced as well. If you want to use the stock stays for the hose I’d probably order one about two inches longer.
https://www.amazon.com/gp/product/B09WYG79R6/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

 

[YamadudeXS650C]

Hi, I’m ready to rebuild the brakes. Do you have any suggestions about where to get front and rear caliper rebuild kits as well as front and rear new hoses. Also rebuild kits for front and rear master cylinders? I’d appreciate it muchly

New brake lines:
Good info here:
https://www.xs650.com/threads/recommendation-requested-ss-braided-brake-line-for-80g.55402/



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[The Phantom]

New brake lines:
Good info here:
https://www.xs650.com/threads/recommendation-requested-ss-braided-brake-line-for-80g.55402/



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I’m glad you piped up. I don’t know if mikes xs is reliable for parts to rebuild my calipers and master cylinders. Can you help guide me to a good source to gets these?

 

[YamadudeXS650C]

I’m glad you piped up. I don’t know if mikes xs is reliable for parts to rebuild my calipers and master cylinders. Can you help guide me to a good source to gets these?

Here are some ideas for a master cylinder, front:
https://www.xs650.com/threads/front-brake-master-cylinders.54945/

For my '82 recently I bought an new aftermarket master/lever complete unit for less than $20. Works great, avoids the rebuild process.

Caliper kits : You'll probably find some ideas here:
https://www.xs650.com/threads/help-with-caliper-rebuild.41676/#post-417265




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[The Phantom]

Here are some ideas for a master cylinder, front:
https://www.xs650.com/threads/front-brake-master-cylinders.54945/

For my '82 recently I bought an new aftermarket master/lever complete unit for less than $20. Works great, avoids the rebuild process.

Caliper kits : You'll probably find some ideas here:
https://www.xs650.com/threads/help-with-caliper-rebuild.41676/#post-417265




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The master/hand lever for the front brake is probably a must for me. Now the rear master, I will want to replace that as well. Any ideas?