Kevin's 1980 XS650-G "Restoration" Thread

[5twins]

I used to use the EMPI brand but now use these from CB Performance. The shafts are threaded closer down to the foot. Cost is about the same as stock replacement screws, maybe even less ......

https://www.cbperformance.com/produ...CgJyMgllu7UFRToDlrgCC9E6OcOSguXAYr6eq-sjR7OAt

You can also shorten them if you like, but they'll fit and work without shortening too. These are the EMPI screws and as you can see, the threaded shaft doesn't come down as close to the foot .....

 

[5twins]

Personally, I'd re-use your original valves and just install these elephant foot screws.

 

[Jim]

That's a fair bit of pitting on those intakes.
My default on parts that could go either way is....
if you have to pull the engine to replace it, replace it while the engine is pulled.

 

[Kevin Kruse]

Hmmmmm... Interesting... I do like mods

So no need to remove material on underside of rocker, just bevel the bottom side of hole?

if you have to pull the engine to replace it, replace it while the engine is pulled

After all, it's only money...

 

[5twins]

Yes, but the elephant "foot" will contact the whole top of the valve stem, so it shouldn't get any worse.

Yes, just bevel the hole with a tapered stone. My pics show it done on an assembled top cover just wrapped in rags to keep the grinding grit out.

 

[Kevin Kruse]

Finished up the SR/XS cam chain guide, ready for service.



Thank you @Jim for the parts and the help!!

Just waiting on more parts, doing some deep cleaning in the meantime..

 

[Jim]

Well done!!!

Rock on, dude.

 

[Its been a long time]

Looks outstanding. I think I'd trust the integrity of that over an unknown quality item from China or Taiwan.

 

[Kevin Kruse]

For future road trips?


I do like the look..

 

[Kevin Kruse]

I'd prefer something like this actually, perfect size and shape, really nice bike.

https://www.xs650.com/threads/newbie-here-trouble-stalling-at-idle.64288/post-797112

Kinda want to bust out the fiberglass and try to make one.. I'm getting side tracked, one thing at a time..

 

[Kevin Kruse]

Happy Labor Day everyone! Hope you're all having a nice day off riding your bikes, I wish I was..

A little update on my top end rebuild progress, this turned into a lot more than just a cam chain guide.. It's true what they say, we don't own the bikes, they own us..

Cleaning up the heads took a lot of elbow grease, definitely investing in a vapor blaster next time.. but they cleaned up pretty nicely.


Also been doing some polishing..


Got new rings from Cruzinimage, took a good 3 weeks to get here but they look like quality rings, forgot to get a picture of them before installing in the cylinders, pistons cleaned up good though. I am a little bummed I didn't order oversize rings to get a smaller ring gap, these ones are all on the upper range of about .016", I guess I'm just not a hod rodder..


Bought a 3" Flex hone and gave the cylinders a few passes, still got some scoring marks inside but I didn't want to go anymore with the hone. I can't really feel them with my nail, maybe just barely on some. Measurements were acceptable. Running it.


Bought 2 new intake valves from 650Central and lapped all valves, also lapped the heads. The intake seats weren't too bad and didn't need as much lapping compared to the exhaust, they had some pitting, and the valves ended up with a little ridge, seat width was still in spec. New valve seals, also did some porting. For the new intake valves he forgot to send me the collets, so I'm using the original ones that were in there, that should be fine right?


Installed the heads, used yamabond 4 on the base gasket both sides, and copper spray on the head gasket, used an SCM gasket kit that @Jim so kindly sent me, and found out it's made of asbestos! Must be the good stuff..


Attempted to rivet the master link on my new tsubaki peanut cam chain but my cheap amazon chain tool kept sliding off and ended up splitting the end , I knew I should've ordered extra ones... Not really sure how I feel about running that so ordered some more.


Ordered the elephant foot swivel adjusters from CB Performance and started modifying the rockers. Got one done but the carbide burr I'm using wore out so ordering some more. Those rockers are hard!


Replaced my clutch pushrod seal and bushing and ordered a NOS one piece pushrod, feels SO much better, there was so much play at the end of the 2 piece rod before. Also noticed the PO covered the old seal with JB Weld tying to seal it... always thought it was just grime. When installing the new seal it took some of the rubber with it, and I did deburr the edge before installing. Also not sure if I should've set it in so far.. Props to @Mailman for removal method.


Fixed a stripped rocker cover hole, made an M6-M7 threaded stud on the lathe, as seen on posts here. Noticed the PO tried "fixing" it by tapping straight through the cover with it on?


Replace the swingarm bushings, it had a considerable amount of play, feels good to change those. The axle has some pretty good wear in it from all the play it had, I just threw it back in.. I turned down a groove on the pivot tube to help the grease get into the spiral, but I think I went a little too wide with it, I wish I left it a little smaller for more bushing contact. Also added an extra grease fitting under the swingarm. My preassembly side play after setting the bushings was basically nothing, so I filed the faces down and ended up around .008" and torqued to around 55ft lbs to get it to fall slowly.


Got the carbs apart for an ultrasonic cleaning and to replace the butterfly shaft seals and up the jets a step from stock because I'm using the foam UNI filters. Also going to order some suzuki plastic floats, my brass ones don't seem to be leaking but I'd like to replace them.


I think I'm going to order this crossover tube also as mine looks a little tired.
https://ebay.us/m/xUiUEe




Phew.. That's all for now, and that's not even everything!

Thank you to everyone that's been helping me so far, I really appreciate it!!! This forum is awesome!

I'm so ready to ride this thing again.

 

[5twins]

Wow, you've done lots of nice work on that thing. Your original fuel "T" still looks OK to me (rubber still intact), I would try it. The trick to sealing them up is to clamp the carbs together with the top and bottom connector strips still loose until the "T" is tight and can't be easily rotated by hand. Then tighten the screws in the brackets while the clamp is still in place .....

 

[grouchie77]

Happy Labor Day everyone! Hope you're all having a nice day off riding your bikes, I wish I was..

A little update on my top end rebuild progress, this turned into a lot more than just a cam chain guide.. It's true what they say, we don't own the bikes, they own us..

Cleaning up the heads took a lot of elbow grease, definitely investing in a vapor blaster next time.. but they cleaned up pretty nicely.
View attachment 356987View attachment 356988View attachment 356989

Also been doing some polishing..
View attachment 357017

Got new rings from Cruzinimage, took a good 3 weeks to get here but they look like quality rings, forgot to get a picture of them before installing in the cylinders, pistons cleaned up good though. I am a little bummed I didn't order oversize rings to get a smaller ring gap, these ones are all on the upper range of about .016", I guess I'm just not a hod rodder..
View attachment 356990

Bought a 3" Flex hone and gave the cylinders a few passes, still got some scoring marks inside but I didn't want to go anymore with the hone. I can't really feel them with my nail, maybe just barely on some. Measurements were acceptable. Running it.
View attachment 356991View attachment 356992View attachment 356993View attachment 356994

Bought 2 new intake valves from 650Central and lapped all valves. The intake seats weren't too bad and didn't need as much lapping compared to the exhaust, they had some pitting, and the valves ended up with a little ridge, seat width was still in spec. New valve seals, also did some porting. For the new intake valves he forgot to send me the collets, so I'm using the original ones that were in there, that should be fine right?
View attachment 356996View attachment 356997View attachment 356998View attachment 356999View attachment 357000

Installed the heads, used yamabond 4 on the base gasket both sides, and copper spray on the head gasket, used an SCM gasket kit that @Jim so kindly sent me, and found out it's made of asbestos! Must be the good stuff..
View attachment 357001View attachment 357002

Attempted to rivet the master link on my new tsubaki peanut cam chain but my cheap amazon chain tool kept sliding off and ended up splitting the end , I knew I should've ordered extra ones... Not really sure how I feel about running that so ordered some more.
View attachment 357003

Ordered the elephant foot swivel adjusters from CB Performance and started modifying the rockers. Got one done but the carbide burr I'm using wore out so ordering some more. Those rockers are hard!
View attachment 357007View attachment 357008

Replaced my clutch pushrod seal and bushing and ordered a NOS one piece pushrod, feels SO much better, there was so much play at the end of the 2 piece rod before. Also noticed the PO covered the old seal with JB Weld tying to seal it... always thought it was just grime. When installing the new seal it took some of the rubber with it, and I did deburr the edge before installing. Also not sure if I should've set it in so far.. Props to @Mailman for removal method.
View attachment 357009View attachment 357010View attachment 357011View attachment 357013View attachment 357012View attachment 357015View attachment 357014View attachment 357016

Fixed a stripped rocker cover hole, made an M6-M7 threaded stud on the lathe, as seen on posts here. Noticed the PO tried "fixing" it by tapping straight through the cover with it on?
View attachment 357018View attachment 357019View attachment 357020

Replace the swingarm bushings, it had a considerable amount of play, feels good to change those. The axle has some pretty good wear in it from all the play it had, I just threw it back in.. I turned down a groove on the pivot tube to help the grease get into the spiral, but I think I went a little too wide with it, I wish I left it a little smaller for more bushing contact. Also added an extra grease fitting under the swingarm. My preassembly side play after setting the bushings was basically nothing, so I filed the faces down and ended up around .008" and torqued to around 55ft lbs to get it to fall slowly.
View attachment 357021View attachment 357024View attachment 357022View attachment 357025

Got the carbs apart for an ultrasonic cleaning and to replace the butterfly shaft seals and up the jets a step from stock because I'm using the foam UNI filters. Also going to order some suzuki plastic floats, my brass ones don't seem to be leaking but I'd like to replace them.
View attachment 357032

I think I'm going to order this crossover tube also as mine looks a little tired.
https://ebay.us/m/xUiUEe
View attachment 357033



Phew.. That's all for now, and that's not even everything!

Thank you to everyone that's been helping me so far, I really appreciate it!!! This forum is awesome!

I'm so ready to ride this thing again.

Christ you got all that done in a day? All I managed to do was buy a gasket scraper from my local Ace.

 

[Mailman]

A little update on my top end rebuild

Looking good! You got a lot of work done! You ought to be back on the road in no time!

 

[Kevin Kruse]

It's got a few cracks and it came out with minimal effort, practically fell out. The rubber is still pliable though, I would hate to see it leak..


@grouchie83 Ha I wish, been on it almost every day since the 22nd minus a few days vacation out of town and a couple root canals at a dentist down in TJ, that was fun..

 

[Kevin Kruse]

@5twins Is this really a factory rivet job? Did they only use master links on early models? I didn’t see any on my old chain.



Makes mine look pretty good Still want to try again though, I have a better plan next time.

 

[Jim]

The thing to remember is that link plate had no sideloading whatsoever on it. The riveting just needs to be good enough to stop the plate falling off the pins. That one above might be ugly, but it's functional.

 

[5twins]

Yes, that's really a factory rivet job, lol. Examine your old chain more closely, it's easy to miss the master link.

Once I apply the rivet tool, I finish by hand peening the link with a small ball peen hammer ......

And I've found that tapping a small "X" cut into the link pins with a small, sharp chisel will keep the rivet tool pin centered on the chain pin as you tighten it down. I also had the issue of the tool pin slipping off the chain pin as I tightened the tool down. This "fixed" that problem .....

You probably don't need to mushroom the ends of the chain pins out as much as you did. Here's one I did before the hand peening ......

I'd try peening the ends of the chain pins on the one you've installed. It just may make it more acceptable-looking and save the trouble of replacing it.

Something else that made my chain riveting easier and better was a replacement rivet pin from Motion Pro ......

I'm assuming you have this type of rivet tool? If so, the MP pin should fit ......

I made the mistake of loaning my rivet tool to a ham-fisted young guy down the street to rivet his drive chain with. It came back to me with the head of the rivet pin all messed up, lol. But this turned out to be a blessing in disguise because the replacement MP pin I got works so much better. It's shaped better on the end so it rivets better and nicer.

https://www.motionpro.com/product/08-0062

 

[5twins]

As far as I know, rivet master links were used on all of the 650s, even the later ones. All the ones I've torn down had them, but the newest one I've been into is a 1980.

 

[Kevin Kruse]

I gave my old chain another look and I found the factory rivet, don't know how I missed it..



Ya I guess mine's not too horrible..

And yes I have the same tool but the cheap amazon one.



There were no rounded pins so I put a radius on one. At first the master link pins were just pushing through the plates and not riveting, I noticed the anvil had a deep pocket so I ground the face down, it was able to rivet after that. It was also difficult to not cock the tool while using it with the supplied lever, I should've used a socket wrench.