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Smiles' Top End Rebuild Thread

Discussion in 'The Garage' started by smiles79, Oct 3, 2018.

  1. smiles79

    smiles79 XS650 Addict

    That's what I wanted to hear, thanks Jim! I better do some exhaust gasket research
     
    JimD54 likes this.
  2. 5twins

    5twins XS650 Guru

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    Inspect the exhaust ports carefully. The old, crushed exhaust gaskets may still be stuck in there. It looks like you still have some cleaning to do. I see lots of gasket remnants on the mounting surfaces where the points/advance housings will go. Dab some paint stripper on them and let it soak, then they should come right off.
     
  3. smiles79

    smiles79 XS650 Addict

    Thank you guys for your input.

    When it comes to installing the cam, is using a dial indicator the beat way to ensure the pistons are at TDC? How do you account for any dwell the pistons have at TDC?
     
    JimD54 likes this.
  4. JimD54

    JimD54 Zoom = Speed X Distance Squared

    Use the timing mark on the rotor.... that's what it's there for.;)
     
  5. smiles79

    smiles79 XS650 Addict

    Fair enough, I wasn't sure if they would be accurate enough. Thanks!
     
    JimD54 likes this.
  6. smiles79

    smiles79 XS650 Addict

    Alright guys, I had a little bump in the road. I was working on riveting the cam chain and, you guess it, dropped part of it into the motor. Fortunately, I was able to retrieve it after removing the jugs.

    It looks like there's a couple spots ripped off the base gasket. It looks like part of the outer surface, it did not rip all the way through. Is this usable in this condition, or does it need to be replaced? The non-hardening gasket sealer I used is still a little tacky, but not soft enough that any stick to my finger. Is this ok like this, or would it be alright if I just out some more on and went with it?

    Lastly, is there an easy way to put the pistons in the cylinders with thet still connected to the connecting rods? I'd rather not take them off again if at all possible, especially so if I don't need any other parts from Mike's (I.e. if the base gasket is ok).

    I feel pretty dumb about this one, hopefully it doesn't set me back too much.

    Thanks!
     
    JimD54 likes this.
  7. JimD54

    JimD54 Zoom = Speed X Distance Squared

    Ask yourself if you want to risk pulling the motor back out and apart if it does leak....
    Yeah, just add a smidge more...
    Nope. No easy way. You'll have to work the rings up into the jugs two by two. After numerous tries at that, you'll wish you'd just pulled 'em off.
    Not to rub salt in an open wound but.....

    36.jpg
     
    TwoManyXS1Bs, Superjet and Mailman like this.
  8. smiles79

    smiles79 XS650 Addict

    Hey Jim,

    Thanks for the reply. I thought I had enough rags in there but I guess not...

    Oh well, at least I found the piece without having to break the motor down more.

    Here are the pictures of the base gasket I meant to attach earlier but if I need new piston pin clips I might as well buy another gasket.
     
  9. smiles79

    smiles79 XS650 Addict

    Third time's the charm!
     

    Attached Files:

    JimD54 likes this.
  10. JimD54

    JimD54 Zoom = Speed X Distance Squared

    If that's the only place... and let me stress that... only place it tore, you'll be OK reusing it. Leave the torn piece in place and just put a tad more sealant on it.
     
    Mailman likes this.
  11. smiles79

    smiles79 XS650 Addict

    Attached Files:

  12. JimD54

    JimD54 Zoom = Speed X Distance Squared

    Don't know, I've never used one of Mikes gaskets.
     
  13. smiles79

    smiles79 XS650 Addict

    Alright, thanks for your help!
     
    JimD54 likes this.
  14. willis

    willis XS650 Junkie

    just my 2cents, but i've found it easier to remove the pistons from the rods and insert them in the jugs while on the bench. Then lower the whole assembly down and reinstall the piston wrist pins. I've done it both ways, just don't re-use the wrist pin keepers if you have removed them.
     
    gggGary likes this.
  15. smiles79

    smiles79 XS650 Addict

    Thanks for the input. That's how I did it last time so I was looking for a way to not have to do that again, but I figure it shouldn't take up too much extra time.
     
    gggGary likes this.
  16. smiles79

    smiles79 XS650 Addict

    Back in the shop today cleaning up and getting ready to reassemble again. I was pretty displeased to see that one of my base o rings got a little munched up since I got the other needed parts in today.Guess ill be paying for more shipping from Mike's!
     

    Attached Files:

  17. smiles79

    smiles79 XS650 Addict

    Well, it also looks like little bits of my head gasket stuck to the jugs when I pulled the head off. Am I corcorrect in my assumption that any potential damage to the head gasket should be dealt with by buying a new gasket?
     

    Attached Files:

  18. JimD54

    JimD54 Zoom = Speed X Distance Squared

    Hard to tell from a pic, but that looks like it's just the copper sealant pulled off. Might be OK to respray and use.
    Keep in mind, your default needs to be... "if in doubt, replace."
     
    TwoManyXS1Bs likes this.
  19. smiles79

    smiles79 XS650 Addict

    It seems like yhere was a bit of the fabric too, not much though. I appreciate your input on all of this. I haven't had luck finding the cylinder o-rings, do you happen to have a part number?
     
  20. JimD54

    JimD54 Zoom = Speed X Distance Squared

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