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74 TX650
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Discussion Starter · #1 ·
I bought this 74 TX650 about 12 months ago as a non goer. It was missing a few bits and looked like it had been parked in the ocean, aluminium was badly pitted and oxidised and steel fittings completely rusted out. At some stage the chain must have come off, a piece was ripped off the top of the top crankcase and the shifter drum bearing housing ground off.

I've done a lot of work on it over the 12months, bought second hand cases, new cam chain and guides, rebore, new pistons , rings and gudgeons, gaskets, seals, stainless fasteners, auto advance unit, plus a heap more parts. Blasted and painted the cases and stuck the motor back together.

I've made a few mods and made a heap of custom parts for it: PMA conversion, single points conversion, ported, remote oil filter and cooler, exhaust pipes and brackets, headlight brackets. Some of the parts I've machined up: Handlebar risers, cable splitter, PMA mounting plate, ally battery box, hand beaten side covers, single seat with cowl, tail light, positive stop nuts, oil filter housing, ally engine mounts and so on.

I do everything myself: Paint, electrical, mechanical, machining, metal polishing, welding, tin work, upholstery, anodising and so on.

This is a project to keep me busy till the end of life, I can never ride it as I have chronic psoriatic arthritis, so fingers have been fused, joints replaced and so on, making for a few limitations and slow progress. With these hands everything takes ten times longer. Luckily, my wife is a good sport, she uses the hammer for me as I can't bash stuff anymore. She also sweeps the floor, cleans my lathe and mill, but shush, she doesn't know I can still do that.

Some pics of my project.
 

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Team Toglhot has done a beautiful job.

It's a shame that your joints have let you down. I don't have arthritis but have worn out knees and elbows so I understand joint pain.
 

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74 TX650
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Discussion Starter · #4 ·
I decided to do a PMA conversion on the TX650, but the kits were very expensive. So, I sourced some new parts on ebay: a stator off a Banshee, a rotor off an XV and an XV reg /rect, for all up cost of $130. I then bought a lump of ally and machined up a proper mount for it, instead of using a butchered Banshee mount. Of course I polished the mount so the lektrisity moves quicker.
Timing was a problem, so I reinstalled the original, timed it statically, then removed the original gear and fitted the new PMA. I then fabricated an ally plate, fitted it to the cover and made marks on cover and rotor.
 

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Discussion Starter · #5 ·
Single points conversion. I wanted to simplify the points system, but I do like mechanical things, so decided to convert the twin points to a single points system. There was a cam available for this conversion, but apparently they weren't very accurate, so I decided to make my own. First order of business was a backing plate which I made from some 3mm thick steel, shaped it on the lathe, filed cutouts for the minting screws and drilled and tapped the plate for points and lube felt.

Next I turned down some stock to 18mm, bored it 8mm, filed the ramps, then cut the keyway. Nope, timing was way off. Did it this way for a few attempts without luck. So, I decided to do it in reverse: Cut the keyway, mount the round stock on the advance rod, time the engine, gap the points, set the points at the midway position and mark where the heel of the points counted the round can and file the ramp. Success, I managed to get the timing for number one cylinder spot on with the correct dwell after only a few files. Next I rotated the cam 180degrees and did the same for the other ramp, success again. It's tiny bit out out, but nothing a quick touch up with a file won't fix. I'll also have to look at the points position on the backing plate, it's almost touching the bowl.
 

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Discussion Starter · #6 ·
I wanted to replace the steel handlebar mounts on the TX with some nice ally risers, but couldn't find any I liked so I made my own from a slab of ally I bought for the job. They came out pretty good I think.
 

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Discussion Starter · #7 ·
I never bothered to start the TX when I got it home, I put a compression gauge on it, the compression was down to around 65 in one, 80 in the other, so I never bothered trying to start it. Instead, I pulled the motor and stripped it down, this is what I found: the auto advance unit was a homemade, bodged up thing, cam chain was stretched, putting the timing out by around 60 degrees. Cam chain guide and adjuster were worn through, carbs were full of gunk, valves seats were pitted, there were a couple of missing pins behind the star on the shifter drum, so no gears, clutch basket was grooved, oil filters were totally gunked up, starter gear spring was loose, there were numerous leaks, the crankcase above the drive sprocket had been torn off, the bearing mount for the shifter drum was damaged, drive sprocket teeth were non existent and the retaining nut looked like Arny had got stuck into it with a sledge.

I had the barrel rebored two sizes over, had the valve seats reground, then sent off for some new parts: new pistons, rings, gudgeons, clips, cam chain guides, auto advance unit, carb kit, new second hand crankcases, gasket kit, seal kit, stainless allen kit, cam chain and probably a few other bits and pieces that I can’t remember now. I had the oil pipe re chromed along with points and auto advance cover. Manufactured a sump filter guard. The rocker shaft bungs are stainless bungs I found on ebay for a fraction of the price of OEMs.

While I was waiting for the parts to arrive, I blasted the cases, barrel, head, rocker cover, and carbs, cleaned them out afterwards with a pressure cleaner about a dozen times. Blew every orifice out at least two dozen times with compressed air and once satisfied they were clean and free of grit I painted the cases, barrel, head and rocker cover silver, polished the side covers, valve caps, dipstick, starter ends, cam chain adjuster housing and breather box, made new pins for the shifter drum, reworked the starter gear spring and started putting it back together in a stand I made for the job.

Once it was all back together, I didn’t fancy starting the motor up on the bench and watch it vibrate itself onto the floor, so I made another stand, with wheels and a rudimentary ignition system. I spun the motor over with my Milwaukee 18 volt drill for a few minutes to get the oil circulated, bolted on what was left of the two into one exhaust, filled the tank, switched it on and hit the starter button. I wasn’t expecting this, but as soon as I hit the starter button, the damn thing roared into life. And by crikey these things are shakers, with the motor going it started walking its way around the workshop, so I pulled out some rope and tied it to the bench grinder stand, then it just jumped up and down every time I gave it a handful. Of course, the carbs were way out of sync, so I put together a manometer and synced the carbs.

End of the engine story: Well, not quite, I thought the motor just looked so bland, so I pulled it apart again, stripped the silver paint off and painted the cases, head, barrel, rocker cover and carb bodies black, polished the carb caps and float bowls then put it back together again with new gaskets. And lo and behold, after priming it, it started straight away again. All good except for a small leak at the base of the barrel. I haven’t fixed that yet, instead concentrating on the frame and fittings.

So, that was the easy bit, the cycle parts have proved never ending, but that's alright, I enjoy my time in the workshop. Being a DIY kind of guy, I insist on doing everything myself, the only diversion from that was taking the frame out for blasting. So to come: New exhaust, seat pan with cowl, ally battery carrier, ally side panels, modified guards, ally tail light, ally brake anchor, stainless brake linkage, ally engine mounts, ally remote filter housing and mounting hardware, risers, cable splitter, ally coil mount, mods to the frame for side panel tabs and battery box mounting, modified fork legs, painting, and did I mention polishing, lots and lots of that: rims, hubs, forks, tree, brake collector, risers, side panels, tail light, battery box, battery retainer, brake ancho, brake backing plate, dust covers, wheel spacers, carbs, valve covers, breather box, cam chain adjuster, carbs, side covers, PMA mount, starter ends, dipstick, remote filter and cooler fittings. In between jobs it was back to the engine for a PMA mount, reg/rect mount, single point conversion, carb sync adjusters, plus a few more bits and pieces.

I can never ride the bike, it’s just a workshop project, so there is no end planned. I’m reaching the end of my time anyway, so after I’m gone the wife can sell it and maybe get some bucks for it, along with all my tools and machinery. I’d really love to take it all with me, but I’ve been told that’s simply not feasible!
 

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You don't generally see a lot of comments here on quality work, that doesn't mean we are not reading your posts.

Beautiful work, great explanations of why, how and how much, lots of good pics. It's an excellent project thread. There is not much to say unless you are looking for cheerleaders.
 

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Nope, doesn't seem to be any interest in TX650s, so I'll move on.
Don't be so sensitive.
You're doing good work and im enjoying reading.
I'm not gonna spam your thread with a pat on the back post.

Just keep putting up your journey and be safe in the knowledge that we are having a good read.

Thanks for sharing
 

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Discussion Starter · #12 ·
As there was no indication that no one had read this post, you'd have to ask yourself 'why on earth would I continue posting if no one is reading, common sense really. Funny thing though, after I said I wouldn't be posting any more due to a lack of interest, suddenly there was interest, WTF. Would you post here if no one was interested???
 

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We're not the type to pat you on the back for doing good work... we'll generally quietly observe.
If you're doing something dangerous or unsafe on the other hand, we'll absolutely chime in.
 

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Discussion Starter · #15 ·
We're not the type to pat you on the back for doing good work... we'll generally quietly observe.
If you're doing something dangerous or unsafe on the other hand, we'll absolutely chime in.
Don't need a pat on the back, also don't need advice from armchair experts, But as I said it's nice to know someone is reading what I post, If no one is reading, why would I post? Just as a matter of interest though, why have you decided to read my posts now I'm not posting any work?
 

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Discussion Starter · #19 ·
A couple of tail lights. I made a steel one first, but didn't really like it that much, so I made an ally one. I had to make it in two parts so I could get in and polish it.
 

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Discussion Starter · #20 ·
Some painting. Tank had one decent size ding and a few minor ones which I bogged up. Frame was blasted, welds cleaned up as best I could, unfortunately, the Japanese didn't know how to put frames together, nor could they weld when they built these bikes, so the frame is rough as guts. Pegs had the forging marks removed, guards were shortened, rear guad had a few dings which I panel beated and used just a smidgen of bog to smooth it out. Seat pan I put together some time ago. I float coated the final coat over 1200 wet and dry, but I haven't bothered polishing anything yet because I'll probably have to repaint further down the track. Bike already has a number of scratches and dings from resting in the workshop.
 

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