Kdobbs '82 Build Thread

[Kdobbs372]

Btw, I don't mean to come off as a harsh asshole, but following directions is kinda important when people are trying to help you. Eventually they'll just throw up their hands and quit offering help.
So take it in the spirit intended... trying to help you.

Ok, again thank you for that gentle nudge...

I have read the card guide and all I can say is WOW! Amazing information and years of wisdom. I have ordered the parts I need.

Now I have a new issue not related to carbs at all. Wondering if you might have some insight.

When I bought the bike it was turning over, but not starting. After new spark plus new battery fresh fuel fresh oil, etc. After several attempts to get the bike to fire up, all of a sudden oil started pouring out onto the ground at the starter. Pouring out from the seal. I did some research and decided it was easier to diagnose and replace the seal having the engine out of the bike. This is also when I decide to address the carbs.

I pulled the starter and opened up the gear box on the other side. What I found was several odd pieces of metal (Please see attached pictures). All the gears seemed fine and I have no idea where the metal came from or what it is. I am hoping this doesn't mean I have to tear the whole engine apart and split the cases. Please look at the attached pictures. The starter is strong of course I am replacing the seal just don't know if there is something else I might be missing.

Any direction you could provide me on this is greatly appreciated.

 

[Jim]

It's (relatively) easy to get the oil dipstick in crooked where it can catch on a tranny gear and get chewed up. I suspect that's what you got there.

 

[Kdobbs372]

It's (relatively) easy to get the oil dipstick in crooked where it can catch on a tranny gear and get chewed up. I suspect that's what you got there.

I guess that's better than internal failure of some kind... Thank you!

 

[Jim]

Make a suggestion? Since you'll obviously be asking questions about more than just the carbs, rename this thread to something like "Kdobbs '82 build thread"... or something along those lines. Just make this an online journal documenting ALL the repairs to the bike. A couple years down the road you'll be glad you did.

 

[Kdobbs372]

Make a suggestion? Since you'll obviously be asking questions about more than just the carbs, rename this thread to something like "Kdobbs '82 build thread"... or something along those lines. Just make this an online journal documenting ALL the repairs to the bike. A couple years down the road you'll be glad you did.

Done - Thank you. And got another surprise tonight. About to post it too.

 

[Kdobbs372]

Hello again, Starting to feel a little degraded with my recent purchase on a 1982 XS 650. Bike looked to be in better than good condition. It turned on electric start spun the engine and never started. I have already got a ton of help with carb and starter issues from Jim. Thanks Jim. But the hits just keep on coming. Tonight I decided to remove the points cover and BAM no points! The the advance cover and BAM no mechanical advance and no advance shaft! I am certain this is not right. Please see pictures. Am I totally screwed? Is this something I just need to find all parts and replace? Do I go back with points?
Any advice or direction is again greatly appreciated.

 

[jetmechmarty]

Hello again, Starting to feel a little degraded with my recent purchase on a 1982 XS 650. Bike looked to be in better than good condition. It turned on electric start spun the engine and never started. I have already got a ton of help with carb and starter issues from Jim. Thanks Jim. But the hits just keep on coming. Tonight I decided to remove the points cover and BAM no points! The the advance cover and BAM no mechanical advance and no advance shaft! I am certain this is not right. Please see pictures. Am I totally screwed? Is this something I just need to find all parts and replace? Do I go back with points?
Any advice or direction is again greatly appreciated.

Your bike doesn’t have points. It has a TCI. The spark is controlled be a black box mounted under the battery box. The trigger is mounted on the stator.

You’re not screwed. All good so far.

 

[Jim]

'82 didn't have points. It has Yamaha's first generation electronic ignition called the TCI (Transistor Controlled Ignition). No worries about it being first gen, they hit it outta the park on the first try.... it's a good system. TCI consists of a dual output coil, an igniter box and a pickup. I see your pickup is installed.

Look for a black plastic box like this one...

 

[Kdobbs372]

Yes! I know where that is. I removed the battery box to repair and paint. Had to remove that unit. Here it is. Wow! I feel much better. Thank you all!!!

 

[Jim]

Now the bad news (maybe). Those boxes are gettin' a little long in the tooth. I mean, the're 40+ yrs old. Odds are pretty good it still a good, functional box. 'Course, there's still a good chance it's shot craps. Only way to know is put it back together and try it, there's no real way of testing 'em. There's a forum member here who repairs 'em, and if it's beyond repair, me and @jetmechmarty both make a harness that'll take a Suzuki box that's cheap..... so there's workarounds if it comes to that.
Fingers crossed, it's a good box.

Now show us your coil.

 

[Jim]

Now that your thread is a build/rebuild journal, tell us a bit about it and your plans for it. And of course... we love pics here. Show us what you got!!

 

[Kdobbs372]

Here you go. They look new?

 

[Jim]

Good and bad.... That's a Honda MP08 coil, which is an excellent upgrade choice. If it looks new though, that's bad. The repop MP08's are made in China. No personal experience with 'em, but being from China, I'd question the quality.
Used Honda MP08's can be had off of Ebay relatively cheap. That's what I run in my bike. By all accounts, they're indestructible.

 

[Kdobbs372]

Good and bad.... That's a Honda MP08 coil, which is an excellent upgrade choice. If it looks new though, that's bad. The repop MP08's are made in China. No personal experience with 'em, but being from China, I'd question the quality.
Used Honda MP08's can be had off of Ebay relatively cheap. That's what I run in my bike. By all accounts, they're I guess there’s no way to tell whether it’s a rep pop or the original?

I guess there’s no way to determine whether it’s a repo or an original Honda?

 

[Kdobbs372]

Went back and looked at it. It doesn’t look new. It just looks clean. There’s some marks and scratches and other indications that it’s been around a while, but it still looks to be in good shape.

 

[Jim]

I have read the card guide and all I can say is WOW! Amazing information and years of wisdom. I have ordered the parts I need.

That carb guide was written by @5twins and @grizld1 . Both excellent techs and teachers. Sadly, Griz passed away a few yrs back, 5twins is still alive and kicking though.

Yeah, there's a wealth of knowledge here.

 

[5twins]

If that is a real MP08 coil, it will be clearly marked .....

 

[Kdobbs372]

Nope. Mine are not the real MP08 coils…

 

[jetmechmarty]

Nope. Mine are not the real MP08 coils…

You have options. You can run those. I’ve been on 650 forums for over 20 years and the Chinese coils have never enjoyed a good reputation. I wouldn’t run it without a spare if I was taking a trip.
MP08 is a proven reliable and economical choice.
Dyna and Accel offer coils for this application. My XS1100 has been running with Dyna coils for several years. No complaints.

 

[Kdobbs372]

Thank you. I am going to buy a good & tested MP08 and run with it.