I got the 650 running previously and was driving it around the neighborhood. As soon as I started it though it was apparent that a pretty bad rattle was still present. It was certainly coming from the top end so I immediately thought the valve clearance might need to be adjusted. Well I replaced the cam chain, adjusted the valves, and the noise continued.

I took the top end to a shop and the recommended replacing lots of parts, pretty much tearing it down and replacing it all. Not too surprising, they are a business after all. I decided to go with it though because there were some obvious signs of scoring on teh clyinders and the rocker arms had some pretty nasty flat spots. Whats a little more money for the XS650 anyways?

The clyinders are now bored 3 over which means I can only bore them one more time before I will need to get new sleeves or new cylinders altogether. Anyways this time around I used all OEM parts. I am sick of lack luster aftermarket parts. That is easier said then done as rocker arms are long discontinued. Pistons and rings are also discontinued in the size I needed. Thank you ebay.

A friend from work helped me reassemble the bike. The reassembly was not without issue but it went pretty well. I am tired of using Yamabond as a liquid gasket. This time I am using only regular gasket with no extra liquid gasket. During my first rebuild I could not get rid of the oil leaks without using Yamabond on both sides of the gaskets. This makes dissambling the bike later a real pain in the ass. Well during that first rebuild I was using aftermarket Athena gaskets from MikesXS. This time I am using OEM and so I am hoping for better results.

There are a couple areas you have to use a liquid gasket though because there is no real gasket. Instead of using Yamabond there I am trying out Hylomar universal blue. Several forum members swear by it. I couldnt find it in a local shop so I had to buy it online. It was a tad expensive but if it works then its worth it. The important thing is that it seals without ever drying. You are supposed to be able to separate the parts later, then rejoin them and have just as strong of a gasket surface. Its like a sticky note, it stays sticky. Well it went on just fine. Time will tell if it works as well as some claim it does.

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Smll Med Lrg new gaskets	Smll Med Lrg misc new gaskets, washers, o-rings.	Smll Med Lrg new tail light lens. The old one was cracked and was loose	Smll Med Lrg several forum members swear by it, this is my first usage
Smll Med Lrg painted and ready to go	Smll Med Lrg new rocker arms and adjusting nuts	Smll Med Lrg old parts	Smll Med Lrg
Smll Med Lrg new valves	Smll Med Lrg	Smll Med Lrg new pistons and rings	Smll Med Lrg
Smll Med Lrg	Smll Med Lrg	Smll Med Lrg	Smll Med Lrg bored 3 over
Smll Med Lrg	Smll Med Lrg	Smll Med Lrg	Smll Med Lrg yeah, i dropped the cam chain down the center after getting pistons in place, doh
Smll Med Lrg	Smll Med Lrg new carb gasket	Smll Med Lrg i am explaining something, god knows what	Smll Med Lrg we made a pretty good mess
Smll Med Lrg engine back in, exciting stuff	Smll Med Lrg	Smll Med Lrg ignition back in place	Smll Med Lrg oil filter removed
Smll Med Lrg pretty dirty, i could clean it or replace it but I would prefer a modern paper filter element	Smll Med Lrg oil pump is behind that gear, same one that drives the tach	Smll Med Lrg	Smll Med Lrg
Smll Med Lrg	Smll Med Lrg theres the oil pump, this one looks pretty good but I plan to replace it anways, its cheap	Smll Med Lrg pre oil pump screen, screen is ripped	Smll Med Lrg screen needs to be repaired, these stupid things are 70 dollars
Smll Med Lrg	Smll Med Lrg screen repaired and fortified, some screen surface blocked but there is still plenty of surface	Smll Med Lrg there is some blockage in the oil passage	Smll Med Lrg it was part of some prior owners pre oil pump screen, go figure
Smll Med Lrg some other debris, probably a cam chain guide piece	Smll Med Lrg old pump looks really good and is still in spec, will replace anyways because its cheap	Smll Med Lrg	Smll Med Lrg
Smll Med Lrg	Smll Med Lrg	Smll Med Lrg	Smll Med Lrg i put some hlyomar on this surface as well because this gasket it old
Smll Med Lrg	Smll Med Lrg	Smll Med Lrg new oil filter from mikes xs, not their biggest fan but this is a modern paper oil filter	Smll Med Lrg
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Smll Med Lrg not too ugly. I dought that this will cool the oil much, but every bit helps	Smll Med Lrg old lense was cracked	Smll Med Lrg	Smll Med Lrg
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