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Thread: 1974 XS/TX650 rebuild

  1. #11
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    th62's Tools
    A nice new rotor arrived this morning. A trip out to wingfield in order to find a big lump of aluminium to make a mounting bracket from is in order now.

    Tell you what though, knock Chinese made products all you like, but both the stator and rotor are excellent quality. Compared to the original Japanese made ones from the 70s, these are superb.

    I suspect that the kit suppliers in America get theirs from China, for a lot less than I paid, get them to make a mount and sell the kit for $400.
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-win_20200831_08_55_34_pro.jpg   1974 XS/TX650 rebuild-win_20200831_08_55_22_pro.jpg  

  2. #12

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    my only known experience was a pair of headlights for Sable which had water in one side, looked very good and came with the bulbs, zero complaints..........

  3. #13
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    th62's Tools
    What? Think you may have the wrong thread.

  4. #14
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    th62's Tools
    Finished off the stator mount for the PMA today. I bought a couple of slabs of aluminium, thickest I could get was 25mm, so I settled for that. That meant making a 10mm spacer. After waiting ages for the bandsaw to cut the slab down to a size that would fit in the four jaw I chucked the square slab and made it round, dished the underside to clear the crank bearing mount, bored a 60mm hole through the middle and drilled a couple of holes for mounting.

    Next came the spacer: Turned down a 70mm round ally bar to fit inside the stator windings and turned down a couple of locators either side to locate the spacer under the stator and to locate the spacer inside the base, thus making sure the stator is mounted central. Drilled a few more holes and tapped them, then stuck it all together.

    Drilling and tapping all these holes scratched the hell out of the ally, so I mounted spacer and base in the lathe again and used some emery to get rid of the marks.

    Fits on the engine nicely, just have to file a woodruff down to match the 6mm keyway in the rotor to the 5mm keyway in the crank. After that, solder some terminals on the end of the stator leads, yeah I know, I'm a rebel.

    Next job is to turn up a cam for the points. I'm going to convert the twin points system to a single, lots of messing around here trying to get the points firing at the correct intervals.
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-win_20200905_16_52_04_scan.jpg   1974 XS/TX650 rebuild-win_20200905_16_16_10_scan.jpg   1974 XS/TX650 rebuild-win_20200905_15_53_44_scan.jpg   1974 XS/TX650 rebuild-win_20200905_15_53_11_scan.jpg   1974 XS/TX650 rebuild-win_20200905_15_51_53_scan.jpg  

    1974 XS/TX650 rebuild-win_20200905_15_50_03_scan.jpg   1974 XS/TX650 rebuild-win_20200905_15_49_36_scan.jpg  

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    Home-PC (09-08-2020)

  6. #15
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    greenie's Tools
    Whoever acquires this bike from you when your finished fixing it up, will have one hell of a decent reliable motorcycle.

    It's a credit to you that your going to such detail, well done.

  7. #16
    Supporting Member tonyfoale's Avatar
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    tonyfoale's Tools
    Great job. It is always nice to see work done properly.
    Personally I prefer to make new stuff rather than repair old stuff. I cannot imagine taking on a bike so degraded as your starting point. I take my hat off to you.

  8. #17
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    th62's Tools
    Modified the fork legs: Removed the lower mudguard mounts on both legs and the caliper mount on the left leg, ground everything down smooth and polished both legs. I also discarded the speedo drive and replaced it with a stainless bush and ally dust cover I spun up, pressed together and polished.
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-hub2.jpg  

  9. The Following 3 Users Say Thank You to th62 For This Useful Post:

    freddo4 (09-14-2020), greenie (09-13-2020), tonyfoale (09-13-2020)

  10. #18

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    form over function?

  11. #19
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    th62's Tools
    Not really, it's more functional than it was 46 years ago, and a lot shinier

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    greenie (09-15-2020)

  13. #20
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    th62's Tools
    Resurrected the swingarm bearings today. The shaft was badly pitted so I turned it down .20mms to 21.8mm. The swingarm bushes were stuffed so I turned up two new ones from Delrin. When drilled, the hole in Delrin comes out slightly smaller than if it was drilled in steel. Unfortunately, not small enough, so the shaft and bushing fit was still a little too sloppy for my liking, so I turned the bushing outer diameter a little larger than an interference fit in the swingarm bushing hole and pushed the bush in place, this compressed the bushing material by .20mm taking the bushing bore down to around 21.8mm. Excellent fit. There's always more than one way to skin a cat!
    Attached Thumbnails Attached Thumbnails 1974 XS/TX650 rebuild-win_20200921_14_17_01_pro.jpg  

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