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Smiles' Top End Rebuild Thread
- Thread starter smiles79
- Start date
smiles79
XS650 Addict
Well it's been pretty cold in Missouri lately and between that and having to take the jugs back off a couple times, work has been slow. It got a bit (not much!) warmer today so I figured I've had enough of a break and I need to get this damn camshaft and cam chain installed.
I neglected to take pictures but, well, it's on there! Getting the chain wrapped around the camshaft was the trickiest part. I tightened the head down a bit with the bolts that go by the spark plugs and holes. Then I removed the bearings from one side of the camshaft and set it in the head making sure it was lined up correctly. I laid the chain on the cam and twisted the wire that was tied to each end together to hold it in place while I installed the bearings. Used a socket to drive the bearings on to the cam and I was good to go!
As for the riveting, that could have gone better. The tool I have isn't the best and I tried riveting it with the pins used to remove links, and that didn't go great. Once I figured out to use the right pin the flare is kind of off center, but I think it'll be fine.
Here's to hoping the rest of this goes better!
I neglected to take pictures but, well, it's on there! Getting the chain wrapped around the camshaft was the trickiest part. I tightened the head down a bit with the bolts that go by the spark plugs and holes. Then I removed the bearings from one side of the camshaft and set it in the head making sure it was lined up correctly. I laid the chain on the cam and twisted the wire that was tied to each end together to hold it in place while I installed the bearings. Used a socket to drive the bearings on to the cam and I was good to go!
As for the riveting, that could have gone better. The tool I have isn't the best and I tried riveting it with the pins used to remove links, and that didn't go great. Once I figured out to use the right pin the flare is kind of off center, but I think it'll be fine.
Here's to hoping the rest of this goes better!
Your avatar sez Iowa?
smiles79
XS650 Addict
Moved to Missouri a couple years ago, guess I never changed it.
Cool. How far from KC?
smiles79
XS650 Addict
About 45 minutes or so, are you from the area?
North of KC.... Gladstone to be exact.
smiles79
XS650 Addict
I've been there a time or two!
smiles79
XS650 Addict
Well I succeeded again at forgetting pictures, but the rocker box is on. I went to the store to get an oil can and oiled the can chain and bearings nicely. Them I put some gasket sealer on the head, assembly lube on the cam, and dropped it on. Had to use the head bolts to get the rocker box to seat all the way. I used all copper washers on the top and it looks pretty snazzy!
smiles79
XS650 Addict
So I realized my gasket kit didn't come with the cam seals. What is everyone using? These are what seemed the closest for my '75, but it says they're for TCI engines:
https://www.mikesxs.net/camshaft-seals-pk-2-sdd-25-40-6.html
https://www.mikesxs.net/camshaft-seals-pk-2-sdd-25-40-6.html
For about $15 more you can get a Tourmax seal kit that has all the seals. If you keep the bike, you'll eventually need 'em. I took a chance and ordered 'em (same part #) and it turns out they're ARS... the Japanese company that made the original seals. Good stuff.
To answer your question, yes. Those will work.... 25-40-6 is the correct size.
To answer your question, yes. Those will work.... 25-40-6 is the correct size.
smiles79
XS650 Addict
Thanks again Jim!
smiles79
XS650 Addict
Well, I finally got everything torqued and the motor installed in the bike. I went to install the advance assembly, and noticed the little pin that goes in the cam that located the plate that the advance weights mount to is missing. I have a couple in the way, is it possible to install it with everything assembled?
I also bought a new drive chain (Izumi 530 110 link). What does the 530 mean? Do I need to trim this chain?
I also bought a new drive chain (Izumi 530 110 link). What does the 530 mean? Do I need to trim this chain?
Yes, it is possible to install the locating pin in the cam for the advance assembly with everything assembled.
530 is the chain size, the size of the links (length and width). Yes, 110 is a bit long and will need to be shortened. Stock size was 104 links. I never actually count the links, I string the chain on and figure out where to cut it after stretching it tight.
530 is the chain size, the size of the links (length and width). Yes, 110 is a bit long and will need to be shortened. Stock size was 104 links. I never actually count the links, I string the chain on and figure out where to cut it after stretching it tight.
You can also dremel off the butt end of a drill bit that fits the hole to make a pin.
XSLeo just did this. http://www.xs650.com/threads/the-81s-alive.54759/#post-593025
I've done it before.
XSLeo just did this. http://www.xs650.com/threads/the-81s-alive.54759/#post-593025
I've done it before.
smiles79
XS650 Addict
Just breather tubes. Route hoses just below the back of the bottom of the engine.
smiles79
XS650 Addict
Well, I put the first 50 miles on the rebuild, thank you all for your help! I'm pretty pumped to be able to add this to my list of accomplishments.
