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Discussion in 'The Garage' started by Doug79, Nov 7, 2019.

  1. Doug79

    Doug79 XS650 Addict

    I tore my motor completely apart two years ago. I reassembled the bottom end about a year ago so it's good but on Tuesday, I pulled all the rest of the parts out to finish assembling the top end. It didn't take long to realize that I didn't remember how it all goes together. I can assemble the big parts but I bought every nut, bolt, washer, steel and copper and all chromed, so I have what looks like at least twice as many as I need and have no memory of what gets a copper washer and what doesn't. I threw in the towel and ordered a Climber manual. It came but is poor excuse for an overhaul manual but does have a real good exploded view of the engine along with good cam timing info. I think between that and laying out and sorting all fasteners I will do ok. Once again, tho, I have managed to make it way harder on myself than it needed to be.
    YamadudeXS650C, gggGary and Machine like this.
  2. azman857

    azman857 '80 XS 650SG Rider Top Contributor

    Chiltons manuals are OK to a point. Factory service manual is best. Haynes are good.
  3. Jim

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

    How about assembly instructions with color pics? Have a look here.
  4. grizld1

    grizld1 Grumpy old man Top Contributor

    For free downloads of the factory service manual (1978 and forward, but the engine section will be the same for all motors from TX650A forward) and parts manuals with exploded diagrams, go to https://www.biker.net (thanks, Jean Akers!). For engine assembly, the most complete manual I know of is The Yamaha 650 Engine, by Hans J. Pahl. The book isn't cheap, but it's full of detailed, high quality photos, and contains step-by-step tear down, inspection, and assembly instructions for every component in the motor, organized sytem by system. Available from Amazon.
    YamadudeXS650C and Jim like this.
  5. Ipa62

    Ipa62 XS650 Addict

    Follow Jim’s write up, can’t imagine you would need more than this.
    YamadudeXS650C, 59Tebo and Jim like this.
  6. Doug79

    Doug79 XS650 Addict

    Holy cow! I have done mechanical work my entire life and have used countless manuals. I have never seen anything done to this level that would allow someone who has never changed a light bulb to assemble the engine. Needless to say, my laptop will be going to the shop with me. I am not doing this project with a mind of becoming an expert on engine overhaul so it is great to run into someone who is! Thanks!
  7. Jim

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

    Thanks. I wrote that for RobinC. He had no experience building an engine. Using that how-to he got it done in fine style. :)
  8. 5twins

    5twins XS650 Guru Top Contributor

    One of my number one rules for engine work, especially the re-assembly part, is .....


    Even though I've cleaned all the parts already, I give all the gasket and sealing surfaces a final wipe-down with lacquer thinner just prior to re-assembly. This will remove any traces of oil that have happened to get on there, even body oil from your fingers.
    Mailman, Superjet, Raymondo and 2 others like this.
  9. Jim

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

    Yes, cleanliness is everything. Perhaps I should have emphasized that more.....
    You'll notice in the pics I have blue masking tape over the openings keeping things clean as you progress.
    Mailman, Superjet, Raymondo and 2 others like this.
  10. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Jim, Mailman and Raymondo like this.
  11. Raymondo

    Raymondo XS650 owner, fettler, setting out on a journey Top Contributor

    The level of helpful advice on this forum!
    Jim, Mailman and Superjet like this.

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