83 xs650 Startup Frustrations: Advice Appreciated

[Tlted_Jelli]

@gggGary gotta love those manufacturing defects. thanks for helping me think through this one. i cant believe i didnt notice that while putting it together. already emailed Mikes and ill probably call them tomorrow. i also ordered some 3.2mm and 3.5mm steel rods to try to remedy the loose pins.

i took calipers to the original locating pins and they are 2.9mm and some change. given my calipers are very old and tolerances im gonna say they are 3mm. i should be able to high grit the 3.2mm or 3.5mm to a perfect press fit.

 

[Jan_P]

OK progress
Thinking out loud...
If the Aluminium part is defective the first option would be to contact the seller see if he can provide a replacement

If the hole, in the cam is to large I would look into make my own pin as mentioned the shaft of a drill .
Which can be bought in many sizes .. If the part sticking out needs to be smaller than in the Axle .Then grind it down a bit
It can be made with press fit into the axle if need be --- and then some Locking chemical it will last as in the proverbial " hundred years "

if you use the stronger chemicals as in the carburetor angle bar .You cant get it loose if you try.

 

[Tlted_Jelli]

Thanks @Jan_P
I emailed mikesxs about the aluminum spacer/rotor being a manufacturing defect.

I also ordered a couple 3.2mm and 3.5mm steel rods.

The original pins look to be ~2.9mm. I should be able to use high grit sand paper on the rods until they press fit.

 

[Tlted_Jelli]

Thought I'd try to 3d print a solution. Wonder how it will hold up

 

[gggGary]

Worth a try?
get the gap welded shut?

 

[Tlted_Jelli]

That'll be the next solution. I only have a flux core welder right now. I think the rotor is stainless. Doesn't feel like aluminum. I'll have to try to magnet test it

 

[gggGary]

I'm pretty sure, aluminum.

 

[Tlted_Jelli]

Gave Mike's my honest feedback. I'm working to have my own part machined at my job or welded over. I don't have my own machine that can tig aluminum.

 

[Tlted_Jelli]

So a wonderful gentleman where I work named Ulysses helped me out and TIG welded over that gap for me. Everything is running beautifully now.

Also does anyone know what size thread and count this may be. M12? Wanna put in a brass "plug"

 

[WideAWAKE]

Might wanna provide some context to your mystery pic.

This whole tread has been about your ignition, pic looks like some sort of steering stem/triple tree???? Maybe I’m way off.

 

[jpdevol]

Might wanna provide some context to your mystery pic.

This whole tread has been about your ignition, pic looks like some sort of steering stem/triple tree???? Maybe I’m way off.

Top fork clamp....steering stem bolt??

 

[jetmechmarty]

https://www.dimecitycycles.com/yamaha-xs650-steering-stem-bolt-washer-set-oem-90105-14102-00.html

 

[jpdevol]

Also does anyone know what size thread and count this may be. M12? Wanna put in a brass "plug"

Yep, if that's what is in the pic, I don't think brass is a good idea there: needs to be a 14mm (1.5pitch ?) bolt that can torque to 40ftlbs (per book)

 

[Tlted_Jelli]

Yeah sorry for throwing in that random bit. But thank you for the assistance as always gents!