‘78 XS650E total rebuild

Niels B

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A while back bought a lot of xs650’s, 2 of those were in good running condition with minor issues, while the 3 others were either in pieces or partly in pieces. One of the ‘78 was 80% assembled but in need of a total overhaul. After cleaning the bike I polished the tank - dismantled everything and renovated as I took it a part. The engine was ugly but after a good clean in the vapor honer and partly in the ultrasonic cleaner it turned out ok. Transmission now installed with new bearings and seal, next step flywheel and closing up the cases.
Meanwhile I got friendly help to get the frame painted up - hopefully engine will be ready when the frame returns. Have a good weekend you all.
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46th Georgia

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A while back bought a lot of xs650’s, 2 of those were in good running condition with minor issues, while the 3 others were either in pieces or partly in pieces. One of the ‘78 was 80% assembled but in need of a total overhaul. After cleaning the bike I polished the tank - dismantled everything and renovated as I took it a part. The engine was ugly but after a good clean in the vapor honer and partly in the ultrasonic cleaner it turned out ok. Transmission now installed with new bearings and seal, next step flywheel and closing up the cases.
Meanwhile I got friendly help to get the frame painted up - hopefully engine will be ready when the frame returns. Have a good weekend you all.
View attachment 213380
You had better watch out for those painters!
 

Niels B

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Slowly and steadily moving along, had 3 sets of starter motors - all between terrible and rusted up to somewhat salvageable. One was so rusted up that I wasn’t sure how to proceed,(should have taken pictures before I attacked them). Anyhow got one back to life and another one back to life except missing the long stags bolts that holds the end together. The third one I believe I can make work too but also missing the stags. Tomorrow the one I plan on using will get new seals etc. had 2 sets of carburetors in awful condition - one set is now useable, however need to check I have the correct jets and needle for the ‘78E ( think it’s jetted for my ‘75.
Here is a few pick ( all parts have been through light cleaning in my vapor honer using super fine glass beads and thereafter 30-60 minutes in the ultrasonic cleaner @60C, to get all the sediments and remaining dirt out. Here’s a few pictures of the progress. Have a nice evening out there.
 

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5twins

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It looks like you have a '74-'75 carb set there so that's what you will need to base your jetting on.
 

5twins

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Yes, you jet these carbs, or base your re-jetting on the year of the carb set, not the year of the bike you're putting them on. The main and pilot jet sizes are tailored to the needle and needle jet sizes and chosen to work with them.
 
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