Top End Rebuild

xs1961 · Posted: October 25, 2008, 4:43 am Post subject: Re: Top End Rebuild

Yeah.Never again.
Takes 20 minutes to blast & the rest of the day to clean out all the oilways & threads .. Still riding this one with my arse clenched waiting for the dreaded seize-up....Reckon I mustve done a thorough job though - 700 miles & no problems.. Cool

yamaman · Posted: October 25, 2008, 8:21 am Post subject: Re: Top End Rebuild

xs1961 wrote:

As you can see I havent worked-out how to use the 'quote' facility... Embarassed

Just press the quote button, you can delete whatever you want from the post except the stuff in brackets at the start & finish

weekendrider · Posted: October 25, 2008, 8:52 am Post subject: Re: Top End Rebuild

weekendrider wrote:

or you can just write it out

[ quote=insert user name here ] extra space between brackets so the software won't create a quote box [ /quote ]

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

There is a torque spec given for the studs. It's listed in that chart that Yamaman linked to on the Australian web site. That's a nice little chart. We should probably all download and save a copy for quick reference .......

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

RG, if you get the complete engine gasket set from Mike's, it will contain the o-rings and valve guide seals - no need to buy them separate. The only other oil seals involved here are the ones in the little points and advance housings. As I mentioned, I didn't even replace those as they weren't leaking and could be accessed later with the engine in the frame if need be.

Jake68 · 650Rider Supporter Joined: Mar 23, 2007 Posts: 841

xs1961 wrote:

Yeah.Never again.
Takes 20 minutes to blast & the rest of the day to clean out all the oilways & threads .. Still riding this one with my arse clenched waiting for the dreaded seize-up....Reckon I mustve done a thorough job though - 700 miles & no problems.. Cool

Blasting..here is what I learnt..

Blasters tell you, "never blast a complete engine"...N*ts. Utter N*ts. They dont want you to do that because its inexpensive.

If an engine is complete and oil tight..great..if its not..you cant do it..and I still wouldnt clean an engine in parts, because you can never get ride of all the blast media. If you do an engine in bits YOU KNOW that there is gonna be some inside.

Just make ally plates and gaskets for exhaust and inlet ports, seal with pipe and bolts and clips all breathers..leave side cases ON..blast entire engine..steam clean..paint with Acrylic and remove side cases and polish.
This will give the most durable finish, that can be re-done whenever required.

The type of blast cleaning I did, just causes media to go everywhere...you can never be sure..the first 4 minute run of my engine carried a tablespoon full of media into the pump filter, and God knows where else..

Like I said, blast engines complete and make gaskets etc...if oil and air cant get out, media cant get in.

xs1961 · Posted: October 25, 2008, 11:33 am Post subject: Re: Top End Rebuild

Mine were vapour blasted, thats probably why they were relatively 'easy' to clean out... ran lots of hot high-pressure water/detergent through all the oilways etc. .. Time to un-clench my ringpiece about now I reckon...

Jake68 · 650Rider Supporter Joined: Mar 23, 2007 Posts: 841

Yeah mine were too...But "my" blaster hit it with grit first for some reason Sad

Vapour is much much better, but I still think your acryllic silver paint finish is really good !

If you havent found any media in the filter, stop worrying...

You have checked the filter havent you? Smile

LOL

xs1961 · Posted: October 25, 2008, 11:41 am Post subject: Re: Top End Rebuild

Checked the filters 3 times so far & not a speck ... Cool

Retiredgentleman · Posted: October 25, 2008, 11:45 am Post subject: Re: Top End Rebuild

5twins; thanks for the the info. Haven't decided yet, who will be my parts supplier. For sure, I'm going to take a beating on the exchange rate. The Canadian dollar has gone into a free-fall...................dam, world financial crisis Sad

Jake68 · 650Rider Supporter Joined: Mar 23, 2007 Posts: 841

Sincerely though RG...

Do get your decks checked and make sure those nuts arent bottomed out..

I think those studs stretch more than people realise.

weekendrider · Posted: October 26, 2008, 12:04 am Post subject: Re: Top End Rebuild

Yamaman my apologies, you did answer my question.

5twins. Thanks for "pointing" it out.

Opened the link but not my mind. Just gave it a cursory glance.
Thought is was the same torque specs as my manual.

yamaman · Posted: October 26, 2008, 6:05 am Post subject: Re: Top End Rebuild

No wuckin furries mate Wink

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

I'm not sure where that chart came from. Those guys might have gathered all the info and drawn it up themselves. I agree with pretty much everything listed except the max value of 11 ft/lbs for some of the M6 fasteners. I've always seen them speced at from 5 to 8 ft/lbs. Years ago, when I first started torquing these, I used that max (8 ft/lbs). Eventually, I stripped one. I rarely go over 7 on an M6 fastener now, especially on these old bikes. I would never even try 11.

yamaman · Posted: October 26, 2008, 11:43 am Post subject: Re: Top End Rebuild

5twins wrote:

I'm not sure where that chart came from.

It says at the top of the page, copied from a Yamaha XS 650B manual.
The manual gives m-kgs settings, they have obviously done there own conversions and made a blue there! My conversion for 1 m-kgs = 7.2 foot pounds
So I'd say the m-kgs is correct, just check the conversions before you use!
Well spotted 5twins

Retiredgentleman · Posted: November 23, 2008, 4:43 pm Post subject: Re: Top End Rebuild

Just an up-date on my top-end work, as there seemed to be quite a lot of viewers on the post.

Lots and lots of cleaning, its been a few years since I'd done this work and I had forgotten how much parts cleaning there is. Only 20.000 kms on the bike, so I wasn't surprised to find cylinders/pistons etc. were in spec. Valves have been lapped and gasket surfaces have been thoroughly cleaned. Opened up the starter motor to check on the brush wear, and again found that wear was minimal.Normal brush length is .630" and mine were only down to .587". Commutator showed almost no wear and only needed clean up, which I did with Auto-sol. Maybe the PO's were kickers?

So, I will be ordering Cam Chain, Front Cam Chain Guide,Gasket Set, Oil Seal Kit, Rings and circ clips.

Its all good fun.................not as good as riding, but its just part of the enjoyment of these old bikes.

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

Time to get the Dremel out and hit those ports Smile

pumps · Posted: November 23, 2008, 5:04 pm Post subject: Re: Top End Rebuild

Hey RG you're just too darn organized!

Retiredgentleman · Posted: November 23, 2008, 5:40 pm Post subject: Re: Top End Rebuild

Yeah pumps, trying to be careful, I don't want any screw ups on this project. I'm still trying to live down my fork seal caper where I put the seals in up-side down................too much work doing things twice!

gordo · Posted: November 23, 2008, 9:28 pm Post subject: Re: Top End Rebuild

Hey RG,nice job on cleaning those part's up,my question is this,are there gosket's between the head and rocker boxes?I have a weep of oil on #1 spak plug coming from the rocker box.

pumps · Posted: November 23, 2008, 10:21 pm Post subject: Re: Top End Rebuild

OK RG, let me tell a story on myself that happened today. Workjing in the bike barn putting sheeting up on the inside. I bought a new blade for the circular saw. Somehow I got the blade on backwards....didn't cut worth a damn but it did cut. My next door neighbor called me on it.

yamaman · Posted: November 23, 2008, 11:18 pm Post subject: Re: Top End Rebuild

Did the same thing with my chain saw once Pumps! Embarassed

Retiredgentleman · Posted: November 23, 2008, 11:57 pm Post subject: Re: Top End Rebuild

gordo;
No gasket between head and rocker cover. Use 3-Bond 1104, its recommended by Yamaha. The good 3-bond 1104 is grey in colour, but apparently there is a replacement of the same name that does not work as well.
Yeah pumps, I feel your embarrasment.

weekendrider · Posted: November 24, 2008, 1:06 am Post subject: Re: Top End Rebuild

Retiregentleman have the intakes had the big ridges ground already?

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Yamaha xs650