What have you done to your XS today?

I finally fixed the starter drive. I've had the bike for ten years and I've never used the starter.
When I got the bike I touched the starter button once and heard a terrible sound so I didn't ever do it again.
Since then I read up on it and knew what the problem was so I've kicked it for ten years.
Anyway I thought while I'm there I'll just replace the clutch plates too.
Long story shortened I put everything back together no problem and tightened down the cover.
Then I looked over and saw the large washer I left out.
There my troubles began... because I hadn't paid close enough attention when I took it apart I could not figure out where the washer went. Consult the parts diagram, no help, thanks Yamaha!
Thankfully this forum exists and I found the thread that solved my dilemma. :)
Anyway, got it all back together and the starter sounds... less horrible now but I'll probably keep kicking it anyway. And the clutch works fine.
Regarding the starter gear fix, since my gear was pretty chewed up I used a new one from Mike's with a NOS clip.
One thing I noticed is the original gear has more of a V-shaped groove for clip compared to the new gear from Mike's that has a more U-shaped groove. Did Yamaha change to this U-shape in later years?
Starter_gear_compare.jpg

The OEM clip wire was 2.90mm diameter compared to the Mike's clip that was 2.80mm.
The NOS clip fit in the new Mike's gear ok and was in spec for drag without having to squeeze it.
I checked the clip from Mike's for the heck of it and it was a couple of pounds lighter and would have needed a bit of a squeeze get it in spec.
The only other thing of note is that after ~42K miles the original clutch friction plates still measured in spec, which surprised me.
 
Yeah I'm aware and on a fresh rebuild I definitely expected some but that's only a few hours of run time. Like I said the yellowish material is what's throwing me off....no idea what that's from. Even looked at all my teardown and assembly pics.
The yellow stuff, did you happen to install kevlar clutch plates?
 
Came home from work this afternoon and reinstalled the clutch cover. I used Yamabond on the cover side of the gasket as well as the lower half of the engine side to hopefully ensure a leak free seal. I know it'll be a bear to get off down the road if I need to get inside but I'll fight that fight when it comes. With a brand new clutch and probably less than 1000 miles a year it should be quite some time.
While I had it apart I also double checked and I was missing the thrust washer under the tach drive...found it stuck inside my original side cover so I installed that correctly. Hoping that helps some of the noise I was hearing from that area.
I didn't fill with oil yet. Going to let the Yamabond set up for a day then snug the bolts a tiny bit more before adding fluid and testing.
 
Almost got stranded with the chopper at a local cruise night tonight. I posted a few weeks ago about a possible ignition switch or other electrical issue with me losing all power to the bike. Rode to cruise night and started spritzing.....tried to turn bike back on and sure enough no power. Fiddled with the switch for a half hour with no luck. Was able to find a local store owner on the main drag who lent me some tools to pull my seat off...because of course I took mine out of the bike last week. Was able to get into my electronics box and jump power from the battery right to the ignition and ride it home...just no lights.
I have a second ignition/power switch here i bought when I first thought there was a problem so I'll swap it in tomorrow.

Clutch cover seems to not be leaking anymore but still some oil spraying back....very little. Have to check for leaks again but it may have been residual just making its way off from somewhere.
 
Regarding my starter drive fix & clutch replacement a few days ago.
I pulled out the kick start shaft a bit when pulled the cover off.
I thought I got it reseated properly but after I buttoned everything back up and refilled the bike with oil I discovered I had un-tensioned the kick start shaft some how.
So I had to drain the fresh oil and remove the cover again. Redoing the kick start shaft properly only took a minute but... it still annoyed me that I had to do it.
Lesson learned.
 
Took it out today for short ride. Stopped and killed it to test the starter a few times.
Kicked it a couple of times too just to be sure.
Omg, I didn't know what a properly functioning XS650 starter sounded like. Now I do! :D
Need to adjust the clutch a bit for the new plates as well.
I'll take it out for a longer run later this week. It's so damn hot now.
 
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Window of Alternator
I though about the Key on the axle ..and went the other way need another key and it is a lot of work taking it off insert the
key and then the holders -- paper shims for radial --play and then succeed hitting the woodruff key.
Best time of year would like to ride some even if the weather has been cool. 12 --15 Celsius Range But short nights
Tuesday 2 weeks ago only 2 at a spot where there can be hundreds of bikes --- . in fine weather Some rain showers but still fine evening.

I tightened it to spec and plan ride some for evaluation I then remembered seeing new bikes have paint spots so one can se if it has moved.
Some paint and then i remembered I had some plastic for making helmet visors

Could have made a better job .Dont know if it can withstand a little heat but it is hard material i believe it was called lexan
polycarbonate
can barely see it on the Picture. gear pedal mirror and the ugly centerhole

A bit soldering and adjusting and it appears charge a little higher on the short test ride



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TAFFY GETS A SHAKEDOWN.

Following the bypass surgery, around the M-Unit, to direct feed power to the ignition; today was the day for a test ride.
10 turns around the industrial estate = 10 miles, all seemed good. Confidence gained I took a trip to the Seawall on the Bristol Channel = 10 miles.
Killed the engine and took in the sea view for 15 minutes.

Back on the bike and I travel inland looping through farmland back towards town = 15 miles. In towards town to my local bike mechanic as he wanted to see the bike in the flesh = 5 miles. Mike seemed impressed with the build, and offered some free advice plus the number for his bike electrician Gavin.
Off to my local bike dealership for a mooch around and a cold drink = 5 miles.

All together about 55 miles.

Taffy runs well at higher speeds; not so cleanly at low to mid rpms. But Taffy didn't falter onto one cylinder; which is a positive.

More to do:
1. Further carb work.
2. Adjusted clutch eliminated slip, but neutral still a bugger to get, moving or standstill.
3. A good clean and polish.

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