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Yam_Tech314's official build thread

Discussion in 'The Garage' started by G_YamTech_314, Nov 28, 2018.

  1. Okay, so I torqued the bolts down... now I’m digging through the forum t put the rest back together... stumbled upon the tidbit of info that there’s a “plug” on the end of the locator pin for the shifter forks. It really only goes together one way, but is THIS shiny bit on the end the plug they’re referring to?

    Attached Files:

  2. Next on my list for questions I can’t find answers to... is it normal for one of my clutch basket gaps to be tight? The outer clutch basket teeth are preventing the fiber discs from smoothly being installed... is it okay to sand this? It’s a clutch basket from eBay...

    Attached Files:

  3. Got some good stuff done today. I was able to remove, and wire wheel the valves, as well as remove all the exhaust studs from the cylinder head. Really debating sending it away for vapor blasting... The top end would be the most visible from onlookers, and the side cases would look great polished. I'm alright with the bottom end being just hand cleaned because it's not as easy to see, and will see the most road dirt anyways.

    Next up is machining, and some tool purchases to start assembling the top end. We are entering chapter two of the engine build at this time. Finally!

    Attached Files:

    Raymond, MaxPete, Jim and 2 others like this.
  4. Brassneck

    Brassneck XS650 Guru

    If you have the engine apart anyways, and are replacing seals, etc. then vapor blasting is a great idea. You'll appreciate it when it's done and will look great. It's a very satisfying feeling putting a very clean and bright engine back together. From my experience, you'll regret not doing it when you have the opportunity to do so, and once you start rebuild it, there's very little chance you'll want to tear the engine down to do it later.
  5. Mailman

    Mailman Hardly a Guru Top Contributor

    Don’t underestimate what can be achieved with just elbow grease!

    But you will see it! Think how impressed you will be every time you crawl underneath to change the oil! :D
  6. Mailman, Great point... I dunno. The bottom end is already together. Not to mention the amount of time it would take to make it look as good as yours... I'm very impressed that you did that by hand. Show me where I can see your process of the cleaning and I'll think it through.

    Brassneck, speaking of seals, how do I go about removing the valve seals?

    On another side of it, I've also debated painting the bottom end black because it's already clean, just a sanding, and masking tape will do the trick.

    Black bottom with a very clean original top end would be satisfying as well.
    Raymond, gggGary, Jim and 1 other person like this.
  7. 5twins

    5twins XS650 Guru Top Contributor

    The valve guide seals just snap on and off the tops of the valve guides. There's a lip on the seal and a groove in the guide for it to snap into.
    gggGary and G_YamTech_314 like this.
  8. Greyandridin

    Greyandridin Got nothing to do and all day to do it XS650.com Supporter Top Contributor

    Geeze I was just crawling underneath mine to try and spot an oil leak
    I 've got 2 elbows but not sure on the required grease to go with them
    Does look good though
    Raymond, Jim, gggGary and 2 others like this.
  9. Brassneck

    Brassneck XS650 Guru

    If I recall , with the valves & valve springs removed, the seal just pulls off the valve guides and replace with a new one.
    Jim, gggGary and G_YamTech_314 like this.
  10. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    I would suggest that you put some oil on the tops of the valves before you slide those guide seals on.

    Raymond, Jim, gggGary and 1 other person like this.
  11. In school we learned to prevent cutting seals by using condoms... Once it's in fully, cut it and pull it out. Never hurts to use protection... Lol!
  12. Mailman

    Mailman Hardly a Guru Top Contributor

    I talked about it here once, post #9

    I used a whole variety of small brass and plastic bristle brushes, scotchbrite pads with common household degreasers like 409, and I also bought an engine cleaning kit from Harbor Freight that was very handy.
    And a variety of Dremel brushes to do the finish cleaning.
  13. 59Tebo

    59Tebo 59Tebo Top Contributor

    Teacher: "How do you spell 'tedium'
    Tebo: "P-A-I-N-I-N-T-H-E-A-S-S. Tedium". :laugh:
  14. Spent the rest of the day on and off just tidying up the garage. This is definitely the cleanest, most organized the workspace has ever been. Every tool accounted for and in it's home (usually the case anyways) and all the parts left for the build are consolidated into boxes to throw empty ones in the attic. More floor space than ever since I moved the toolbox, and for the first time in months I have nothing unnecessary on the work bench. Goodness, this feels good!

    All the boxes under the right side of the bench are XS parts. The pile of parts grows continually smaller over time, though there are also boxes hiding behind my mini air compressor, the pile was originally three boxes tall, and covered a whole portion of my garage wall.

    In other news...

    Took a ride on the rebel 300 today as well... It is lacking very much in the power department, and it's giving me the motivation I needed to really get this build back on track.

    Here's to hoping I can keep my head in the game this time around. I'll be the owner of this bike for two years come November 3rd. That means you've all put up with me for almost two years. Thanks for that!!! :cheers:

    Attached Files:

  15. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    It has been a pleasure - you’ve learned a lot, had some fun and saved a nice old bike and that makes it all worthwhile IMO.

    G_YamTech_314, Jim, Mailman and 3 others like this.
  16. Would I be safe to use these tools on the INSIDE of the cylinder head? Like in the combustion chamber, on mating surfaces, etc? Also, would it be worth my time to use a grinding head and smooth out the intake ports? Or would it be a really dumb idea that only a pro should do? Would porting even really make a difference???

    I ask about safety of the tools for the inside because I've decided against vapor honing. One, I'll save money doing it myself.

    Two, it'll be more rewarding.

    Three, the local guys didn't sound like they cared AT ALL over the phone so they aren't getting my business.
    Mailman and Jim like this.
  17. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    Going racing? Checking HP and torque on a dyno? Is this something you're driven to do to see if you can feel it in the seat of your pants? As for me, I answer no, no, and no. If you answer otherwise, I understand completely. As for me, I just want as many trouble free miles as possible. As far as torque and HP, I throw my leg over my 41 year old XS1100, the XS650 doesn't stand a chance in that dept. XS650 is still about my own personal grin factor. Big power doesn't play into it. But, if you're into making more with what you have for your own personal satisfaction, then I do understand completely. :twocents:
    Mailman, Greyandridin and Jim like this.
  18. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    I totally agree with Marty on this. If you want a mid-sized bike with big-sized power - buy a modern 600cc sport bike or even a Suzuki SV650 which has about 50% more power than an XS650 (75 HP versus about 53 HP) and weighs about 30 lbs less.

    Trying to wring much more out of an XS650 may result in a quicker bike, but it also could to lead to durability issues later and, I could be wrong, but I suspect that standing beside some highway with a broken bike is unlikely to increase your fun-factor.

  19. Good points guys. I'll stay away from all the excess labor and just have fun putting it back together the way it came. As far as cleaning methods go though... What are your thoughts on brass brushes on mating surfaces? Also, steel brushes on find, and combustion chamber? What material is the combustion chamber? Looks like steel?
  20. Raymond

    Raymond XS650 rider, fettler, setting out on a journey XS650.com Supporter Top Contributor

    You can use brass brushes or whatever you want to clean inside the combustion chambers or exhaust ports or whatever. But NOT on the mating surfaces. Oil or gas under pressure will always find its way through the tiniest of gaps. Better to use 5T's suggestion of paint stripper. When that has loosened the dirt, wipe off with a cloth, use a wooden scraper or very careful use of a green pan scourer. Some people use a soft alloy scraper and still others use a razor blade But it is all too easy to leave tiny scratches. This is my personal opinion and others may advise differently . . .
    Last edited: Sep 11, 2020

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