New owner

[Jan_P]

Everything is possible .But the transmission is solidly built and there are not excessive loads
Especially since the clutch can slip.
Abuse can happen and cogs go off --it happens
But I would not suspect the gear box as first thought
I would check the clutch operation first
And then consider a bore scope before taking the engine out
Is mileage known ?

 

[Raymond]

Another place to buy bits - https://yambits.co.uk/?gad_source=1&gclid=EAIaIQobChMImrnls9OZiAMVJ07_AR2nUwzDEAAYASAAEgIEwPD_BwE

They sell lots of parts for XS650, some NOS (new old stock) and some is parts they get made specially. Not very easy to search their website so sometimes I do a Google search to get to the right page. I've had very good service from Yambits.

Another place to go is - https://www.cmsnl.com/yamaha-xs650_...MI0evS1dSZiAMVF5RoCR19Nw3CEAAYASAAEgL5hPD_BwE

They sell a lot of XS650 parts, fairly expensive, but their website has all the parts diagrams so useful as a reference source. Often, you can identify a part and the information will tell you the new part number if it has been superseded. Then you can use that number to search other websites.

I've also bought from Fowlers of Bristol - https://www.fowlersparts.co.uk/?gad...MI1YyJsdWZiAMVJJVQBh3FLhIIEAAYASAAEgIovfD_BwE

 

[Adamc]

Another place to buy bits - https://yambits.co.uk/?gad_source=1&gclid=EAIaIQobChMImrnls9OZiAMVJ07_AR2nUwzDEAAYASAAEgIEwPD_BwE

They sell lots of parts for XS650, some NOS (new old stock) and some is parts they get made specially. Not very easy to search their website so sometimes I do a Google search to get to the right page. I've had very good service from Yambits.

Another place to go is - https://www.cmsnl.com/yamaha-xs650_...MI0evS1dSZiAMVF5RoCR19Nw3CEAAYASAAEgL5hPD_BwE

They sell a lot of XS650 parts, fairly expensive, but their website has all the parts diagrams so useful as a reference source. Often, you can identify a part and the information will tell you the new part number is has been superseded. Then you can use that number to search other websites.

I've also bought from Fowlers of Bristol - https://www.fowlersparts.co.uk/?gad...MI1YyJsdWZiAMVJJVQBh3FLhIIEAAYASAAEgIovfD_BwE

I too used thier services during the rebuild of Taffy. Great advice, quick delivery and general good service and availibility.

 

[laakkeet]

Thanks for the links Raymond! Shame about brexit tho, ordering from UK means tolls and taxes so the costs tend to go up nowdays.

Everything is possible .But the transmission is solidly built and there are not excessive loads
Especially since the clutch can slip.
Abuse can happen and cogs go off --it happens
But I would not suspect the gear box as first thought
I would check the clutch operation first
And then consider a bore scope before taking the engine out
Is mileage known ?

I tested the gears again today and was able to find 1st, neutral and 2nd. When I try to go for the 3rd it doesnt click to gear and kinda stops going further. Can shift back down tho.

Did you look at the sump filter? Did you know it is there.

Checked the sump filtert and man it was pain to get loose. Quite literal pain as I smashed my hand with the rubber mallet pretty hard

The filter had very tiny amount of metal but overall pretty decent. Ran a magnet trough the oil left over in the cover and got very small amount of metal from that too.

Noticed that the fresh oil I put in and drained left some metal in the bottom of my drain pan. I did test the electric start before draining and it didnt sound healthy. From what I read, those can shed some metal?

Overall the filter seemed to be in a decent shape, might put buying the Heiden design filter on hold for now.

Finished the day by deciding to put the sump back on since the gasket didnt break. I mean it needs replacing for sure but figured it’s worth a shot to see if it holds oil. It didn’t.

To top off my day, I decided to make sure I tightened the bolts properly and managed to snap one of the bolts, so that’s going to be headache and a half.

But what done is done and some lessons are learned the hard way. Off to buy a torque wrench tomorrow..

 

[Kevin Werner]

When refitting the sump, carefully clean both gasket surfaces, lightly lube both sides of the gasket and assemble carefully. You do jave to crawl around with a scraper to get the engine surfaces. I use a spade x acto blade carefully. Use standard torqueing procedure of starting in the middle and working out. My sump gaskets don't leak, come off in one piece and have been reused several times.

 

[Jan_P]

I tested the gears again today and was able to find 1st, neutral and 2nd. When I try to go for the 3rd it doesnt click to gear and kinda stops going further. Can shift back down tho.

There are some adjustments possible You get the idea there .Please look in a service manual
Try to spin the wheel some shifting also

https://www.xs650.com/threads/star-shaped-gear-selector-out-of-alignment.28174/

Manual perhaps there
https://thexscafedotcom.wordpress.com/2011/01/10/xs650-manuals/

 

[laakkeet]

I printed out couple manuals I found here on the forums, but didn’t catch that one. Seems to be great, thanks! And thanks for the link, ill be sure to give that thread a read. Haven’t really started on the transmission problem but thats on the menu after I fix the sump filter fiasco.

As for refitting the sump, I think I did it pretty much the way you describe but to be fair the gasket is done for. Didn’t lube the underside but I was pretty sure if I try to take it off the cover it would break.

Then again, my bad on even trying to use it. Not to mention tryin to tighten the bolts further to stop the leak. Best I can hope for is that the bolt snapped from close enough that it’s easy to remove after I remove the sump cover again.

Btw feel free to let me know if I’m posting too much. Just super stoked to work on the bike and cant shut up about it. Wife is getting antsy since I’ve pretty much been MIA since I got the bike, so might have to take some off days from the bike and the forum..

 

[laakkeet]

Is mileage known ?

Forgot to include this:

If the odometer is to be trusted it’s around 33 000 km / 20 000 miles.

 

[Jan_P]

Forgot to include this:

If the odometer is to be trusted it’s around 33 000 km / 20 000 miles.

Should normally not need an engine split Not for the Gearbox nor the Cylinders
If not time has made changes ---Oil things up and start gradually

 

[nj1639]

Like Jan_P mentioned, try spinning the rear tire when shifting. These bikes don't shift well when not rolling.

 

[650Skull]

Mid 77 Yamaha changed the shaft spline profile. The 5th gear overdrive is made for the shaft profile change.

There is a tech bulletin Yamaha put out about this. Has the engine vin # when the change occured

 

[Kevin Werner]

In a perfect world ( ) the gasket will stick to one side or the other and be reuseable. Mine might weep some but I never have a drop of oil on the floor. The grungy motor bottom may be road scum kicked up by the front tire.

 

[Niels B]

First of all get that torque wrench - or a couple - one for smaller torque and one for the more heavy duty stuff.
Secondly, if you need to get to the gear you can get by with opening the bottom only and work the gears without messing with the top end.

 

[Niels B]

You need this one https://www.chopsource.com/deluxe-yamaha-xs650-engine-stand-brackets.html

 

[laakkeet]

Been a bit under the weather so havent got much done. Except going down the ”Best Oil” rabbit hole and reading up on ignitions and PMAs. Going to run the stock stuff until it wont run no more and found a reasonably priced 20w50 oil to use. Good stuff!

Oh, and got myself a set of torque wrenches. Lucky for me the bolt I snapped was original so I got it out with pliers. Replaced with generic bolt.

Was checking on the clutch cable adjustments and ended up cleaning stuff up:

After couple cans of the ol’ elbow grease it cleaned up good enough for now. Going to tidy things up after I take the engine off. It really is very satisfying to clean up these old engines!

Was going the check the starter housing as it didn’t sound too great when I tested it previously, but the cover wont budge. Tapped on it lightly but didn’t dare to use too much force with the gears and all. Any tips on getting it off?

Gotta order a chain and new sprockets as it’s missing. Need few gaskets too, as the left cover gasket was busted and the sump filter gasket was toast too. Most likely a new gasket for the starter cover plate and probably right side cover aswel.

 

[jetmechmarty]

Going to run the stock stuff until it wont run no more

If you have a place that can do it, get the rotor rewound. The original is aged out and guaranteed to leave you stranded. Alternatively, send it over here to @Jim for rewind.

 

[Raymond]

Great progress! Cleaning it up is very satisfying. The starters are a bit marginal and there's threads in Tech on the common problems and fixes.

Most of the gaskets you can make for yourself - they say you can use cornflakes packets but I invest in sheets of gasket paper. Those curved little nail scissors are ideal to cut the outline and a set of leather punches to make the screw holes.

 

[laakkeet]

Sending the rotor out to states is probably out of the question, but I’ll check if theres a place where I could get it done a bit closer. Thanks for the tip!

I’ve been looking into ignition/pma set from Vape and initially got the expression that it’s pretty much mandatory upgrade, but I think for now I wont fix whats working.
Besides coughin up the ~700 for the Vape system is easier to explain to my wife, if I’ve been stranded in the middle of nowhere

I tought about getting some gasket paper and cutting them, but I have to order a bunch of stuff from Heiden anyways. The gaskets werent too pricey. I’ll be sure to make templates from the new gaskets for future tho.

 

[jetmechmarty]

Besides coughin up the ~700 for the Vape system

It seems to me that shipping a rotor back and forth would be cheaper.

 

[laakkeet]

It seems to me that shipping a rotor back and forth would be cheaper.

Just checked and I can get the rewind done at Heiden for 175€ plus shipping. Might have to do that down the line.