Stella - 1977D survivor, back on the road.

[DanielBlack]

Electrical exploration still continues when I get the chance, but today I've got more exciting things to report.

Ten months ago I purchased a newly manufactured Craven luggage rack from the UK. Craven didn't have a specific fitting kit for the XS so the plan had been for a colleague of mine with skills and tools to fabricate some simple brackets. Well, one thing led to another and the project sat undone. Until today.

With a bike I can pretty much count on, temps keeping to double digits, and a mutual day off I finally made the 45 mile ride out to his place.

Note: Up until now, 40 miles was the outer edge of max daily mileage for me. Today's 90 felt great except the last 10 or so in bumper-to-bumper.

Back to my colleague: this is the guy who first whispered 'XS650' in my ear. He test rode Stella for me given that I'd never ridden anything more than 170cc and 200# before. It was his nod that put her on the trailer. He's also the guy I mentioned whose father had a circus act with motorcycle riding dogs. Today I saw proof!

I'll have to get a glamour shot for you all, but here's the business end of things. Nothing cut, nothing welded. Everything easily bolted on. I've got some cleaning up to do, paint, matching hardware all around, etc., but she's solidly mounted. No shake, nor shimmy.

 

[robinc]

Wow, how do you train dogs to do that?

Looks good Daniel. Nice job!

 

[Mailman]

All right Daniel, that looks the business! Well done. Now maybe you can shed that backpack eh?

 

[DanielBlack]

Already shed! Rode home today with my bag strapped to the rack!

Aren't those dogs amazing?! I saw one on roller skates, too. Rolling around on just his hind legs.

 

[TwoManyXS1Bs]

The low frame on that rack looks like a nice place to grab while doing the centerstand dance.

http://www.xs650.com/threads/the-centerstand-challenge-lift-assist-handle.46892/

 

[YamadudeXS650C]

I like The Bike Whisperer , and Zavatta's dogs!! Very cool ! The history brings in so much additional meaning and depth.

And the rack looks unique and cool.

Cooincidentally, I decided today to take the rusty rack off my barn find '81 and put it on my '80. I'll report on that later...

 

[DanielBlack]

Just about 4000 miles on the clock in my 13 months of ownership. Time for another 1000 mile periodic maintenance and oil change.

The paper side filter and magnetic sump plugs were all very clean. In the bottom of the sump plate I found some cam chain guide plastic bits along with a very small amount of ferrous starter gear. Nothing to be alarmed about and cleaner than it was at the last check.

It wasn't until this point that I realized I didn't have a spare sump plate gasket. So, with the forced time off the road while I wait for a new one, I decided it was time to explore the right hand cover for the first time. In the recent few weeks she's slipped out of 2nd a few times and it's time to check things out.

Thanks to Pete the steps to get in there were clear as can be.
Build Thread...Special to Cafe Bike

I've gotten as far as the 29mm clutch hub nut and all is looking pretty clean. Plates and springs are all in spec and show even wear. I've got seven friction plates right about 2.9mm. The springs measure between 35.1 and 35.5mm. The 77D supplement replacement values are 2.7mm and 33.6mm, respectively. The clutch housing dogs have some marking, but I don't think too bad. The worst spots are barely discernible by feel. Some marking on the inside cover. A suspect in the popping out of gear, the shift pawl spring is there and looks to be in good shape.

Because I know you all like them, here's a few thousand words...

 

[Mailman]

Well Daniel, you're really digging in there. I can't wait to see what is causing your jumping out of gear problem.
Are you planning on doing anything to your starter gear / spring?

 

[MaxPete]

Looks nice and clean Daniel. Glad the write helped. It looks like the impact driver worked well on the clutch screws.
Getting into the RH side of thenengine really is not a big deal.

VERY nice job on the rack by the way. I’ll bet that will make commuting much easier!

 

[DanielBlack]

Are you planning on doing anything to your starter gear / spring

Weren't you just talking about scope creep?! Ha! Yeah, probably. As long as I find a pair of snap ring pliers before my gaskets come in.

Looks nice and clean Daniel. Glad the write helped. It looks like the impact driver worked well on the clutch screws.
Getting into the RH side of thenengine really is not a big deal.

VERY nice job on the rack by the way. I’ll bet that will make commuting much easier!

The impact driver is great! I've never used one before, wish I had it a year ago.

Yes! The rack makes commuting so much more comfortable.

 

[TwoManyXS1Bs]

Those friction plates look burnt.

I think I see the kickstart shaft shim washer stuck to the side cover. Common. Don't lose it...

 

[TwoManyXS1Bs]

Huh? Double posted...

 

[DanielBlack]

Yup, the washer is mentioned in Pete's write-up. Along with the tip to take care not to pull the kickstarter out.

Burnt plates, huh?

 

[TwoManyXS1Bs]

You could try smellin' em...

 

[DanielBlack]

...like oil.

 

[TwoManyXS1Bs]

If they're the typical cork composition, a finger nail impression should leave a small dent. Burnt plates are harder, and a fingernail shouldn't leave a dent...

 

[DanielBlack]

Yup. Harder than my fingernail. Also the edges of the material is brittle and some can flake off when coaxed. Scratched with my nail there's a slight whiff of what one may call charred. Add those to the list.

Thanks 2M. I knew these photos would raise some points of interest.

 

[MaxPete]

Hmmmm...sounds like a new set is in order Daniel. That could be quite worthwhile particularly with your commuting everyday.

Pete

 

[5twins]

And I see you got yourself a Vessel impact. You should be good pretty near forever with that tool. All I've ever had to do with mine is replace an occasional bit.

 

[Paul Sutton]

Impact drivers are perfect for clutches, can save loads of time compared to screw drivers and hammers and other tricks. Unfortunately I lost my Vessel impact driver between NZ and the UK. Replaced it with the Sealey version which happens to have a bit that fits the clutch screws perfectly. That thermometer has a very low profile, so compact and tidy. Is that how they are made or have you modified it?