Newbie w/ '78 Project

[Qst24]

I bought a ‘77-‘78 XS650 partially-completed project from a local guy who is moving away. He gave me a great deal considering he threw in tons of additional parts, new tires & rims, and even a complete (or mostly complete) second engine. Here's an album with photos of everything that came with the bike (in addition to what's on the bike in the photo above): 78 XS650 Build Parts.

I owned and rode a couple of motorcycles like 10 years ago but have no experience building them. Buuut, I have a space to work and am in no rush, so I'll learn as I go. Ultimately, I think I would like to end up with something that looks like this, considering the steps the previous owner took already, like the CBR-style mono shock:

I would love any advice or recommendations from this group as I figure out how to "eat this elephant."

So far, this seems like the best high-level approach:
1. get the bike running;
2. have someone check the welding the previous owner did & frame integrity;
3. work on body style items (gas tank, seat, etc.); and
4. then deal with design styling (paint colors, etc.).

To get the bike running I know I need to rebuild the engine and the carburetors to start. I have the reference materials recommended on this site: 1) Hans Pahl's XS 650 engine book; 2) Haynes workshop manual; and 3) digital download of the original service manual. I think it makes sense to start by building the second engine that came with the bike:

This YouTube playlist (2Wheel Workshop's XS650 Rebuild) looks like a pretty good breakdown of the disassembly, inspection, and reassembly process, so I will rely on those vids supplemented by the manuals above. I feel reasonably confident (famous last words, I know...) that I can follow the step-by-step to eventually get it taken apart then put back together. The two things I am most worried about are:

1. deciding what parts are too worn and need to be replaced vs those that are fine; and
2. how to clean the disassembled parts, especially the bottom end, which as you can see has a lot of rust/oxidation/corrosion.

Number 1 is not a huge worry, as I'm sure I can just come to the forum and/or google part by part to get guidance. But, on number 2, I've gotten myself confused reading about the different cleaning chemicals and materials. I am worried about using the wrong cleaner and/or material to clean the wrong part and really screwing something up. Taking the disassembled parts to someone to vapor blast sounds easiest but I can't tell if that is overkill.

Oh! Lastly, would love a call out of any specialty tools I should order now to avoid having to stop in the middle of the project to wait for a tool to arrive via mail. For the engine rebuild, I've already purchased based on what I've read on the forum:
1. Japanese philips bits;
2. Chain Breaker
3. Clutch Removal Tool
4. Driver - Socket - Clutch Hub - 27mm
5.Compressor Tool Set - Valve Spring - With Case
6. Pliers - Circlip - Internal
7. Screw Extractor Set - 1/8 - 3/8 - With Case
8. MP-30 flywheel puller

Thank you for any advice, feedback, or encouragement. I'm fucking stoked to be here!

-Quest

 

[Jim]

Welcome aboard!!
Don't think I've ever seen an old Honda Super Hawk tank on an XS before.

 

[Niels B]

Wow, welcome lots of guys here with a lot of knowledge - in addition they are very helpful.
I’m no expert but I have, by now, successfully rebuild 4 engines.
Looks like you are covering the tools pretty well, however may I add that you need internal and external machinist micrometer set, especially for cylinder / piston and ring measures - this way you can determine if you need bore / hone rings and / or piston. Would be a pity to dismantle and reassemble to learn that you don’t have good compression.
Now there’s no saying how many miles on the engine but I would get lapping tool and paste to spice up the valve seat at the least.
I vapor hone or ultrasonic clean all parts - even both sometimes. I use either glass beats or alu beats depending on what result I’m looking for. Attached how it looks after above and some polishing.
Ps alu beats are little rough but great for removing paint from parts.

 

[jetmechmarty]

What kind of clutch removal tool did you get?

I like this one.

Yes, I think you have an elephant. There’s plenty of help here.

 

[Wingedwheel]

Welcome, that doner engine looks a little rough. It’s missing the starter drive, I don’t see a cam in your pics or an advance rod and components. Unless you just want to rebuild it for practice I would look at the one on the bike but just my opinion and it doesn’t mean anything. That looks like an amazing project!