Kevin's 1980 XS650-G "Restoration" Thread

[Kevin Kruse]

Hey everybody, I thought I'd start a thread for my 1980 XS650-G and the work I want to do to it, and for any questions I'd like to ask. It won't be a 100% restore but I do eventually want to get it looking as good as I can with respect to time and budget.

Some background,
I purchased the bike in San Diego from someone who got it from the original owner on a trade, it had been sitting in a garage since '97 and looked to be mostly original without much tampering. It had 21k miles on the clock. He was able to start it and idle with choke but died with any throttle, that was enough for me. My first motorcycle was a 1980 XS400 that I got running pretty good and put some miles on that thing, rides up the coast to San Francisco and one trip out to Colorado and back, always ran beautifully. That got me into the XS models and Yamahas in general, always wanted the 650 since having my 400, now that I've found one and bonded with it I would like to keep it and show it some love.

Some work on it so far since owning it, general maintenance and some mods;
-Oil filters
-Clutch plates
-Cush drive springs
-Rewound rotor (by Jim)
-Upgraded regulator/rectifier
-Plugs/Wires/Caps
-Retarded TCI ignition timing
-Elephant foot valve adjusters (EMPI)
-UNI air filters
-Carb clean
-Rebuilt petcock
-Standard style seat/bars
-Brembo front caliper/rotor
-Fork emulators (MikesXS)
-Progressive Harley fork springs (Part#11-1120)
-Reserve Headlight Unit delete
-Light checker delete
-Blade type fuses
-Voltmeter in dash box
-31t rear sprocket
-Brake booster valve engine breather
-Shortened clutch actuator arm (to help with shifting)
-Replaced with one piece pushrod, new bushing and seal
-Kawasaki KZ305 clutch lever
-GN250 Gonzo Ignition Box (as a backup)
-Top end rebuild (9/18/25)

When I got the bike..


As of now..

 

[Jim]

-Retarded TCI ignition timing

I'll follow along.
Curious... did you add the TCI system or was it already modded?

 

[Kevin Kruse]

So I'm doing my second oil change today since owning the bike, replaced both oil filters on the first one, put about 1500 miles on it so far since purchase. Found some shiny bits in the top filter and 2 plastic bits, that cover was stuck pretty good so made a tool to remove it, worked nicely. And in the sump I found some larger plastic pieces, I'm guessing cam chain guides? I've read they are known to fail and should be replaced, does this warrant an engine removal to replace the guides? Wouldn't mind as I would also like to replace my leaky head gasket while I'm in there.



@Jim TCI was already in and had the factory threaded rivets that I slotted and removed, set timing with a light.

 

[Jim]

So... it looks like you have the TCI, BS34 carbs and a drum rear, correct? None of those came on a US '79. Care to share your VIN? leave off the last 3 digits if you want.

Looks to me like it might be an '80 Special II.

 

[Kevin Kruse]

Correct, VIN is 3G0-007 minus last 3 digits. I'm actually unsure if it's a 79 or an 80. The date of manufacture says 12/79, looking at the ID chart I see 3G0 as 79/80.

 

[Jim]

Yes, changing the cam chain guide requires a top end disassembly, which requires engine removal.

 

[Jim]

Correct, VIN is 3G0-007 minus last 3 digits. I'm actually unsure if it's a 79 or an 80. The date of manufacture says 12/79, looking at the ID chart I see 3G0 as 79/80.

Then your bike is an '80. TCI and BS34's didn't come on a '79.

Funny, my SG was titled as a '79, even though it's clearly an '80 model. I suspect the same happened to yours.

 

[Kevin Kruse]

Seeing those bits I pulled out, would you say it would be unwise to button it back up and keep running it for a few weeks or so while I get the parts and prepare for the job? I would like to get an engine hoist for the job, I really like yours that you made, was thinking of doing that. Some good stuff in this thread https://www.xs650.com/threads/engine-weight.66634/#post-845281

Would be nice as its my only transportation right now, really need to finish fixing my car, maybe it sitting will be good motivation to get that done ha.

 

[Jim]

Yeah, that definitely looks like the guide in all that oil. You can still run it like that (for a short spell, many others have), but be gentle with it. The chain is now slowly chewing through the aluminum base of the guide. That means fine particles of aluminum in the oil. Set up a frequent oil change schedule and baby it as much as possible.

It definitely needs doing sooner rather than later though.

 

[Kevin Kruse]

Got it, thanks Jim!

I'm reading your SR500 cam chain guide thread, I'm thinking I want to give this a shot, going to give it a thorough read..

And what's a good source for a quality head gasket or gaskets in general? All I know is to stay away from Athena gaskets..

Also a source for a cam chain if I need one?

 

[Jim]

Keep checking ebay for an SCM branded kit. They pop up from time to time and are supposedly OEM. I've bought 4 or 5 now and they're good quality in my opinion.

 

[Jim]

Also a source for a cam chain if I need one?

I get mine from Partzilla. I'm sure you're aware by now, but treat MikesXS as a source of last resort. Too much of their stuff is pure junk.

 

[Jim]

You changed your title to '80SG. I believe that should be just a "G" for the SII??

 

[Kevin Kruse]

Yes I have noticed.. Especially with their electrical components, they should have your services advertised front page.

Ah, thank you. Fixed... Thanks again.

 

[Jim]

Here's something to go along with that 31T sprocket....

https://yamahaxs650.com/product/447-big-bore-kit-80mm-750cc/

 

[jetmechmarty]

Also a source for a cam chain if I need one?

I got a couple of peanut chains from Michael Mercury Morse at 650Central.com. His in California and a fast responder. I believe it’s a superior chain for a little money.

I have an XS650G that I acquired from the original owner. It’s all there in case you need info about it.

 

[Kevin Kruse]

Here's something to go along with that 31T sprocket....

Oh, that's on the list... and possibly a 277 rephase. Also that 31t is really working for me, no complaints. For the record I weigh 170lbs, I can see how it might not work for heavier folks.

@jetmechmarty Good to know, thanks Marty!

And just got the GN250 ignition box and harness, nice wiring job! I'll give it a test run soon.

 

[JJames]

You changed your title to '80SG. I believe that should be just a "G" for the SII??

Didn't know that. Mine is a 1981 special ll.

 

[650Skull]

Didn't know that. Mine is a 1981 special ll.

Hey everybody, I thought I'd start a thread for my 1980 XS650-G and the work I want to do to it, and for any questions I'd like to ask. It won't be a 100% restore but I do eventually want to get it looking as good as I can with respect to time and budget.

Some background,
I purchased the bike in San Diego from someone who got it from the original owner on a trade, it had been sitting in a garage since '97 and looked to be mostly original without much tampering. It had 21k miles on the clock. He was able to start it and idle with choke but died with any throttle, that was enough for me. My first motorcycle was a 1980 XS400 that I got running pretty good and put some miles on that thing, rides up the coast to San Francisco and one trip out to Colorado and back, always ran beautifully. That got me into the XS models and Yamahas in general, always wanted the 650 since having my 400, now that I've found one and bonded with it I would like to keep it and show it some love.

Some work on it so far since owning it, general maintenance and some mods;
-Oil filters
-Clutch plates
-Cush drive springs
-Rewound rotor (by Jim)
-Upgraded regulator/rectifier
-Plugs/Wires/Caps
-Retarded TCI ignition timing
-Adjusted valves
-UNI air filters
-Carb clean
-Rebuilt petcock
-Standard style seat/bars
-Brembo front caliper/rotor
-Fork emulators (MikesXS)
-Progressive Harley fork springs (Part#11-1120)
-Reserve Headlight Unit delete
-Blade type fuses
-31t rear sprocket
-Brake booster valve engine breather
-Shortened clutch actuator arm (to help with shifting)

When I got the bike..
View attachment 354340

As of now..
View attachment 354341

Help in identifying XS650's + maintainence tutorials for electrics, gauges and other stuff

https://www.xs650.com/threads/xs650...-other-information-including-xs750-850.30569/

 

[JJames]

Hey everybody, I thought I'd start a thread for my 1980 XS650-G and the work I want to do to it, and for any questions I'd like to ask. It won't be a 100% restore but I do eventually want to get it looking as good as I can with respect to time and budget.

⁹That got me into the XS models and Yamahas in general, always wanted the 650 since having my 400, now that I've found one and bonded with it I would like to keep it and show it some love.

Some work on it so far since owning it, general maintenance and some

Cool history with your xs400. Impressive progress on the new bike. I've never been the sharpest knife in the drawer but FWIW, my xs has been shedding bits of chain tensioner for around 10 years now. It's on my list.