bikesbybruce
XS650 Member
Please forgive me if this subject has already been covered. My 81 had a fried TCI so I went to points taken from a basket case.
Saw the horror stories about cracked cam towers, oversize bushings, etc. I gently honed out the cam bores for the advance rod bushings on both sides with a Dremel and a sanding drum as shown in the picture. Four new bushings that were a no-go at the start went to a perfect fit after about 30-35 seconds. I'd recommend 15 seconds at speed 3 or 4, blow some compressed air through the cam and test fit repeatedly. Make sure you run deep enough to accommodate both inner and outer bushings on both sides. Don't get carried away as the removal rate is quite fast and it leaves a really nice finish in a jiffy. Don't forget to whip out the die grinder with a cutting disc and cut the coil bracket out of the donor bike as well for your two coils that will need to go in the TCI bike. Cheers
Saw the horror stories about cracked cam towers, oversize bushings, etc. I gently honed out the cam bores for the advance rod bushings on both sides with a Dremel and a sanding drum as shown in the picture. Four new bushings that were a no-go at the start went to a perfect fit after about 30-35 seconds. I'd recommend 15 seconds at speed 3 or 4, blow some compressed air through the cam and test fit repeatedly. Make sure you run deep enough to accommodate both inner and outer bushings on both sides. Don't get carried away as the removal rate is quite fast and it leaves a really nice finish in a jiffy. Don't forget to whip out the die grinder with a cutting disc and cut the coil bracket out of the donor bike as well for your two coils that will need to go in the TCI bike. Cheers
