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Thread: 1974 XS/TX650 rebuild

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    th62's Tools

    1974 XS/TX650 rebuild

    I bought a 74 TX650 several months ago as a long term project. I'll never be able to ride it, but I enjoy building rather than riding anyway, so it's worked out well

    The bike was in terrible condition, had to ask the two young fellows next door to get the thing off the bike trailer when I got it home. Way past my physical abilities now

    Every piece of steel was rusted, some of the spokes had rusted completely through, all fasteners were binned, along with seat, battery carrier and a few other rusted bits and pieces.

    Aluminium was badly oxidised and damaged from rough tool use. Motor was free but not running and had sustained some damage from an errant chain: Section of the top crankcase was ripped off and the shifter drum bearing mount had also been sheared off.

    The bike came with a box of spares, mostly damaged: two extra carbs, extra gauges, mags and a set of rusted out spoke wheels, ignition switches, wiring looms, old bearings and so on.

    Auto advance unit was missing, centre stand was broken, quite a lot of damage.
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-1.jpg   1974 XS/TX650 rebuild-2.jpg   1974 XS/TX650 rebuild-3.jpg   1974 XS/TX650 rebuild-extraparts.jpg   1974 XS/TX650 rebuild-extraparts.jpg  

    Last edited by th62; 08-02-2020 at 02:18 AM.

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    First order of business was to tear the bike apart and look at the damage. In their wisdom, the Japanese decided to build the bike so the motor had to be removed from the frame to work on it, and a heavy lump of metal this thing is. The motor can only be removed by laying the bike on tnhe right side, undoing all the mounts and jiggling the motor back and forth while trying to get the motor free.

    The TX is an odd mixture of over engineering and under engineering, some good ideas and some terrible ideas, as I was to find out. OtHer damage was the drive chain, despite being way beyond it's life span, it had been left in service so both sprockets had badly hooked, teeth. The previous owner had fashioned a rough auto advance plate which was at least 90 degrees out. The motor would never have fired up anyway as compression was down around 70/90lbs. Carbs were choked up, valve seats were pitted, starter gear spring had lost all tension, cam chain was stretched so much that the motor couldn't be timed, even with a whopping .30mm points gap and both cam chain guides had lost their linings.

    Other visible damage was to the upper crankcase and numerous gouges in the side covers which would have to be ground out. I located a set of second hand crankcases, so sent off for them and also sent off for a seal kit, a gasket set, two new cam chain guides, a new cam chain, an auto advance unit, some shifter drum pins, valve spring seats, some stainless allen head fasteners, new pistons, rings, gudgeons and a few other little bits and pieces. I also sent the barrel off for reboring and the head off to have the valve seats reground.

    Whilst waiting for the parts to arrive, I stripped the rest of the bike down, throwing out all the fasteners, spokes, seat pan, battery carrier, spokes and a lot of other bits and pieces that were just to rusted to be re used, then set about bringing the alloy back to life, a hard dirty job!
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-stand.jpg   1974 XS/TX650 rebuild-spoke.jpg   1974 XS/TX650 rebuild-side.jpg   1974 XS/TX650 rebuild-shocks.jpg   1974 XS/TX650 rebuild-guard.jpg  

    1974 XS/TX650 rebuild-20.jpg   1974 XS/TX650 rebuild-31.jpg   1974 XS/TX650 rebuild-34.jpg   1974 XS/TX650 rebuild-23.jpg  
    Last edited by th62; 08-01-2020 at 07:54 PM.

  3. #3
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    th62's Tools
    Here's some alloy bits I prettied up while waiting the parts. The hubs were mounted on my lathe for trueing and removal of casting bridges between fins, then smoother and polished. Rims were in a terrible state with lots of tyre lever damage and pitting from heavy oxidising. Tyre lever damage was ground and then rims polished. Engine side covers were the same, most of the dents and gouges I managed to remove then polished them up. Front forks weren't too bad, just badly oxidised. Alsp polished the dipstick, cam chain adjuster, breather box, tappet covers, starter motor ends.
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-31.jpg   1974 XS/TX650 rebuild-33.jpg   1974 XS/TX650 rebuild-35.jpg   1974 XS/TX650 rebuild-36.jpg   1974 XS/TX650 rebuild-37.jpg  

    1974 XS/TX650 rebuild-38.jpg   1974 XS/TX650 rebuild-39.jpg   1974 XS/TX650 rebuild-40.jpg   1974 XS/TX650 rebuild-47.jpg   1974 XS/TX650 rebuild-49.jpg  

    1974 XS/TX650 rebuild-50.jpg   1974 XS/TX650 rebuild-51.jpg   1974 XS/TX650 rebuild-48.jpg  


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