Mailman’s XS2 , pulled the engine for top end repair

Lookin' good!!!

Enamored.gif
 
Meticulous, as usual. Your motorcycle will run better than before after such expert attention. You have risen to the occasion Bob and, as I predicted, you are coming out on top. Well done my friend! It's New Year's day here mate so....
Happy New Year! Keep up the great work! X
Dave
PS And sort out that f#@king petrol tank!
 

Thanks Jim!
Meticulous, as usual. Your motorcycle will run better than before after such expert attention. You have risen to the occasion Bob and, as I predicted, you are coming out on top. Well done my friend! It's New Year's day here mate so....
Happy New Year! Keep up the great work! X
Dave
PS And sort out that f#@king petrol tank!

Thanks David! I’m workin on it. Happy New Years to you too buddy!

You're made of sterner stuff than me. I woulda had those jugs off by now.

I’m trying to be systematic, grab one piece at a time and work it through to the end. What can I say, that’s the way I’m wired! :laugh2:
 
Geeezzz Louise Bob - I’m just catching up and holy cow!

I cannot imagine how all of that black snotty looking stuff got past the fuel filters.....
 
What ever you do don't put that tank back on before you have it sorted.:(. It didn't take very many miles for those valves to look like that. What a mess. Now that you'r a pro at rebuilding the XS there will be guys wanting to send you work.

Yeah, I have a great reluctance to put that tank back on. I’m going to try and figure something out.
I don’t know if I’d call myself a pro at engine building, but I was surprised that I felt much more comfortable working on it this time.
 
Today’s update,

The first thing I did today was give the head a good scrubbing to remove all the metal bits from me grinding the intake tracts. Then I blew it dry and immediately oiled the steel parts so it wouldn’t rust. Threw the valves in and the head is now done!

Edit: I made a critical error at this point that will not be reflected in this thread. I failed to install new valve stem seals while I was rebuilding the head, I simply never thought about them since they were not very old. The melted gas tank liner that stuck to the valves also ruined the seals. I replaced them later after I got the motor back in and running, only to realize the seals were leaking. I was seeing motor oil inside the intake tract. I replaced the seals without pulling the motor again. The how to article is now in the tech section.


6573021C-3675-495A-8184-9AC72409E22E.jpeg
C1D8CD03-F101-40AC-9429-992749127189.jpeg


Wrapped up and put away until needed.
39EA8A22-6EE8-4C25-888C-66638B0E2A59.jpeg


By the way, I just have to comment on these engine cleaning brushes I bought from Harbor Freight. Brass, steel, and plastic brushes are just perfect for cleaning intake and exhaust ports, oil passageways and more, it really makes quick work of it!
879D4DF2-3442-477F-8005-B72DDE123265.jpeg


Then I pulled the cam chain tensioner out, and pulled the jugs off.
F31B117D-11C9-41C4-996C-D7D305AA7BE4.jpeg


I shoved a bunch of towels around the con rods and removed the circlips and wrist pins and off came the pistons.
The rings were not stuck, but they were sticky.
CC037282-C0C4-412F-893A-B6D06BB805A1.jpeg
2035A501-CA69-417B-80F8-000B265085A6.jpeg


The pistons were a bitch to clean up. I never seem to think ahead and get some good quality paint stripper, so I used good old fashioned elbow grease, and they’re now done.
0D74949D-4DD5-4DA0-A094-FA6942211D4F.jpeg


My Hylomar Blue is getting dried up , so I ordered a new tube from Amazon, I got a shipped notice this afternoon, it won’t be here for almost 3 weeks! Oh well, I’ve got plenty to do.
Oh I almost forgot, I decided to go with a new look for my bike, like the Phoenix rises from the ashes, so will my bike!

Edit: This was a joke, that apparently a lot of you took seriously.
19108CBD-72D0-4BA5-ADC0-E0C0458A19ED.png
28A9ACC8-D85A-4FB1-AC6D-8548FF694962.png

Maybe some extended forks and ape hangars too. Stay tuned!
Later, Bob
 
Last edited:
Today’s update,

The first thing I did today was give the head a good scrubbing to remove all the metal bits from me grinding the intake tracts. Then I blew it dry and immediately oiled the steel parts so it wouldn’t rust. Threw the valves in and the head is now done!
View attachment 181975 View attachment 181977

Wrapped up and put away until needed.
View attachment 181978

By the way, I just have to comment on these engine cleaning brushes I bought from Harbor Freight. Brass, steel, and plastic brushes are just perfect for cleaning intake and exhaust ports, oil passageways and more, it really makes quick work of it!
View attachment 181979

Then I pulled the cam chain tensioner out, and pulled the jugs off.
View attachment 181980

I shoved a bunch of towels around the con rods and removed the circlips and wrist pins and off came the pistons.
The rings were not stuck, but they were sticky.
View attachment 181981 View attachment 181982

The pistons were a bitch to clean up. I never seem to think ahead and get some good quality paint stripper, so I used good old fashioned elbow grease, and they’re now done.
View attachment 181983

My Hylomar Blue is getting dried up , so I ordered a new tube from Amazon, I got a shipped notice this afternoon, it won’t be here for almost 3 weeks! Oh well, I’ve got plenty to do.
Oh I almost forgot, I decided to go with a new look for my bike, like the Phoenix rises from the ashes, so will my bike!
View attachment 181985 View attachment 181986
Maybe some extended forks and ape hangars too. Stay tuned!
Later, Bob
! ! ! ! ! ! ! !
I'm not kidding when I say that these wild tins are absolutely fabulous.
I vote for you to polish them up, clean the interior, and run them as is with all their wonderful glory !!
.
.
 
Back
Top