XS650 Disassembly is hard.
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XS650 Disassembly is hard.

This is a discussion on XS650 Disassembly is hard. within the General forums, part of the Caferacer.net Forums category; Way more complex than my old CM400, which, admittedly, is my only frame of reference outside of baby motorcycles, which are super easy. It took ...

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  1. #1
    Senior Member spacmanspif300's Avatar
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    XS650 Disassembly is hard.

    Way more complex than my old CM400, which, admittedly, is my only frame of reference outside of baby motorcycles, which are super easy.



    It took me a couple hours to get the motor out of the frame, build a little block for it, and hoist it with my own two skinny little arms up on a table.

    Then it was an ordeal just to get the head cover off. Holy crap.

    So now I need a chain breaker for the cam chain, and a vernier caliper for measuring crap. I guess I should get a valve compressor too...you can borrow those, though.

    XS650 people: Are there any other special tools I will need? What if I do the bottom end too?

    What's going on with my points cam?




    Yikes! I'm guessing I should replace this. A note: the manual says there should be a needle bearing at either end of the points cam, but I didn't see any. Maybe that's why it's worn so out-of-round.

    I found some metal dust goo on the oil drain plug when I was draining the oil; that's got me worried that maybe I should look in the bottom end, too.

    Money is a major concern. Right now I'm hoping to skate by with cleaning and decarboning everything and just replacing rings.

    Basically....ummm....HELP!

    Finally, a couple shots of my meager shop:




  2. #2
    Senior Member UngaWunga's Avatar
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    Points cams, are just that: cams. They aren't round, or the points would never open or close.




  3. #3
    Senior Member spacmanspif300's Avatar
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    Thanks for clarifying. I wondered if that was it, but a points cam is a new animal to me.

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  5. #4
    Senior Member hillsy's Avatar
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    You should be able to remove the cam / top end without having to cut the camchain. Either by unbolting the cam sprocket or loosening the tensioner.

  6. #5
    Senior Member spacmanspif300's Avatar
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    Negative. Tensioner loosed, no sprocket bolt to be unbolted.

  7. #6
    Senior Member KeninIowa's Avatar
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    Then take the caps off and work the cam out of the chain.

    Don't cut the chain, ever.

  8. #7
    Senior Member crazypj's Avatar
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    Yep, I've never cut a 650 cam chain.
    Remove end covers, remove rocker cover, work bearings out of head (not too difficult) and you have plenty of slack to get cam out
    I dabble in rocket science, when I\'m not picking my nose
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  9. #8
    Member twinsarehot's Avatar
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    howdy spif,

    some of the most important mods are to the swing arm (bushings, go with brass or roller bearings) which is super easy. The forks will probably need to be taken apart, for this you'll need to make a special tool out of some bolts and threaded rods to remove the fork tubes. also consider working on the steering neck.

    you may want to consider getting rid of the points and going with electronic ignition. there are a ton of posts about all the subjects listed above at "http://www.xs650.com/"

    also, these engines are about the simplest thing on the bike.

    the cam chain guides on the xs's are prone to eating themselves away, once the rubber on the guide is gone, you'll start to find bits of metal in the oil. easy, cheap and a must to replace.

  10. #9
    Senior Member Geeto67's Avatar
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    was there any reason to take the mill down to the block? or is this an excersie in doing it just to see what it is like? I am fine with it either way, but if you don't understand that a cam = eccentric movement, then do you know what it is you are looking for?

    Ever tried. Ever failed. No matter. Try Again. Fail again. Fail better.
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  11. #10
    Administrator texmawby's Avatar
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    nice REV'IT! jacket (background). i assume it is an Air?

    Tex
    advocate for the injured, disabled, and urinated upon.

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