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Hey All, So in fixing my last problem with a valve opening while the piston was on a compression stroke, the camchain tensioner guide slipped into the crankcase. I didn't think this was possible, but as have not found the guide laying around my garage, and I forgot to reinstall the tensioner...

That was exactly the problem... but now I have a new problem. Is it at all possible that my rear cam chain tensioner could have slipped into the crankcase? When I reset the camshaft, and removed that camchain tensioner assembly, I did not see the chain guide. I know it was there... I would...

So... I am reassembling the cylinders, Pistons slide in and everything goes fine. I put on the Cylinder Head, again, no problem. On goes the camshaft, timing chain, tensioners, etc. just great. When I manually turn the crankshaft with my wrench, everything moves easily and without...

Good to know! As for the grind, and i am just relaying tech talk, the factory typlically grinds down mating surfaces so they "pair" as mentioned by chris with the cam cover/rockers and the cylinder head. However sometimes through normal wear, an engine's shape will warp, causing the surface to...

Correct me if im wrong, but dont covers need to be matched because of the factory grind on the gasket faces? Maybe a workaround would be to grind the two donor parts to assure the same "flatness"? Either a machine shop can do it, or buy a porcelain tile from home depot and glue 120-180 grit...

Blind plug over the ignotion cover needs to be drilled out. I used a 6mm drill and drilled until it loosened and came out stuck to the bit. The plug is about a 1/4" inch thick, i went slow, very slow so ss not to damage the screw that hides behind it. Since you will have this thing torn...

I dont mean to hijack the thread, but i am in the midst of a topend rebuild, and i am at a loss for getting the cylinders back on the pistons, do i need a piston ring compressor to slide the cylinders onto the pistons? (I left the engine in frame as i did want to get too involved before the bike...

I like it!

Do the valve adjustment screws make valve shimming unnecessary?

I will post some pics tonight, but generally speaking, how serious of an issue is pitting on the valve contacting side of the valve adjustment screws? They are cheap parts so i will most likely replace them, but is it critical to replace them prior to running the bike? They appear to be about...

Yeah, bike pump, patch kit, spare tubes, and probably contact cement or something (dont know if contact cement is safe for use with tire/tube rubber) Im not familiar with cody or kendall... I guess really, im not trying to do the Baja rally, but i need a bike, or rather i need to make my XS...

Yeah, thats pricey too. But definitely an option. My goal is to make it from seattle to cancun via baja and the pacific coast crossing through chiapas, and on to cancun where i know a family that i will be staying with. I could definitely have them sent there, but that means i still have to...

Yeah this may be the biggest/toughest decision i make regarding the bike... i hope... However, in talking with some techs over the weekend, and one who commutes on an enduro with tubed tires, they did not say that tubed tires are bad. Yes, they have their downsides, but they are equally...

For anyone in the Seattle area, and this may be known already, there is a wonderful bike shop: Seattle Used Bikes. They are a shop that focuses on import bikes and somewhat "specialize" in vintage bikes (i.e. yamaha xs's etc.) They are super friendly, quick turn around, and super...

Also, when talking about clearance, which area(s) are of the most concern? Is it that the suspension travel may allow for a larger tire to rub against a fender/frame? or (and I'm assuming this is the bigger issue) is the width of the frame/swingarm the bigger concern? If it is a suspension...

@Ethanl Totally! I plan on heading down to Bend/Sisters in early June, and I'm hoping to have my bike ready by then (barring any major problems, and of course I just doomed myself by saying that...). I will say that at the moment, I am sick of looking at tires, it appears that my only options...

After doing some research, that is the direction i am going with my 1980 xs400g. I want it to be subtle, except for the tires, no way to hide those shinko 705's, those make a statement. But my plan is to get this bike roadworthy, play around and get comfortable/gain riding experience, then im...

Been another long while, and I am interested as well... Any takers?

Okay, I am committed to this project now... Rebuilding/inspecting the top end. Round 1. So first of, I got the glove out. Amazing that it went in via the Right intake, but a majority of the glove was stuck in the left intake valve spring. So, Magic. Here are some pics of my progress, I am...

I feel a bit stupid asking questions, only to find the answer later after a second search, however I think my problem may be terminology. For example, i sheared off what i called a "tappet cover" and freaked out because when i googled the problem everyone was talking about how rare and...