XS650 Brat Build Ep 35, Engine Rebuild Pt 5: 5th Overdrive Install & Bottom End Assembly

In This video I replace all the oil seals, a bent selector fork, install a 5th gear overdrive pinion and driven pinion and assemble the bottom end.

[@KAPANGAAAMASTER]

I can't believe how few likes this videos has. Most assembly videos are really half assed and short, this must be gold for anyoone planning on reassembling their XS650 engine or servicing it.

[@turkeyhornet]

Great video Brodie.....I’m working my way through all your vids whilst rebuilding my 1977 XS🙏

[@2wheelworkshop]

Thanks mate. Much appreciated

[@turkeyhornet]

Is the overdrive gear from another Yamaha bike or an aftermarket item?

[@2wheelworkshop]

It's aftermarket. I got mine from Geoff's XS in Australia but you can get them from Mikes XS as well.

[@thecluelessbiker]

Thank you for the xs 650 videos. It really helps a lot! I'm assembling an engine similar to yours. Thanks again!

[@2wheelworkshop]

You're welcome mate. Thanks for the feedback

[@colenelson7766]

Very helpful with the torque specs. excited about the next one.

[@richiebainbridge2608]

Really enjoyed all the videos. Sold my xs so moving back the Harley project. Thanks from England and I hope I find some one as good as your to help me through the big twin project . Cheers. Richie.

[@Tater-]

another awesome video mate! looking forward to the next one!

[@wanmuhammadfakhrullahwan8078]

👍👍

[@louisvanderwilt5438]

A few more questions, I noticed that you don't use many gaskets. Is there advantages/disadvantages to using gaskets with respect to sealant? It seams that the next tear down would go a lot harder for the separation the two mating parts, not to mention the cleanup. Does the 0.005 in. gasket thickness affect the mating parts assembly? I love watching your videos and I have been saving them for my rebuild. You may want to request the viewer to click on the "Like" button at the start of the videos.

[@2wheelworkshop]

I should have used gaskets on the starter gear cover and the sump plate but I didn't have them and I was impatient. When joining the case halves and fitting the rocker cover sealant is required as it is not a continuous surface. When using sealant you run the risk of lumps of it coming off inside the engine and blocking oil passages so it should be used sparingly. Thanks again for the feedback and I have since started putting "Like and subscribe" animations in.

[@louisvanderwilt5438]

If the Center to Center distance between the drive to driven 5th gear has to remain constant, don't both gears have to be changed for them to fit? I saw that you changed the driven gear but I didn't catch if the driven gear was changed because it was a different size as the original or if you were changing it because it was worn. Wonderful job on this video! The background music was very helpful in watching the video. I thought that the addition of the parts forms and arrows added to you video as well.

[@2wheelworkshop]

Thanks for the feedback mate, I really appreciate it. The manufacturers of the new 5th pinion were able to reduce the spacing between each tooth enough that they could squeeze in an extra one without changing the diameter of the gear. I also changed the driven gear but in hindsight I think it was unnecessary. I find and fix the culprit for it jumping in and out of gear in a later video.

[@pauldumas6784]

Love these videos buddy. I’ve only completely rebuilt one motor, Honda XR650L. Is there a reason why you don’t use assembly lube?

[@OldBiker]

Hi Brodie, when you put the clutch pressure plate on it looks like you miss aligned the hole on the plate with the dot on the inner housing, they should line up as the clutch is balanced, also how come you never used gaskets on the starter and filter covers? Using lots of sealant like that could result in sealant coming off inside and blocking oil passage ways.

[@jerrybigrig9475]

😎👍😎

[@jerrybigrig9475]

Who sells the overdrive gear ..??

[@2wheelworkshop]

I got mine from Geoff's XS in Australia but I know Mike's XS sells them in the US

[@iliasperisteris1059]

Need help g.day I have a 1981 yamaha 650special...hasn't started in 20 years but after cleaning the carbs the bike started the right side cylinder got hot and the left side is running cold...been watching the your videos but for some reason I have come to a dead end with the points been trying to set the timing but all I'm getting is back fire. From the left cylinder....and the right side spark plug still looks brand new like there isn't any fuel...p.s I'm in Greece and can't find parts unless I get them from UK. Or America do you no of any dealers who can ship me parts...any help would be appreciated....

[@louisvanderwilt5438]

One more question, is there anything a person can do to increase the horsepower from the '75 XS650 Yamaha engine? I always found my top-end to be around 85 mph to 90 mph with my stock engine. I think you mentioned that you were at 105 mph with yours. With our interstates at 75 mph, an 85 mph top-end seams a little lean. Maybe some new carbs and Cam?

[@2wheelworkshop]

Aside from the 5th overdrive my engine is stock. I live in Australia so if I mentioned speeds in any of my video's I would have been talking in km. having said that mine will comfortably sit on 75mph and will do more than 90mph. If you want more power you could start with a performance cam (I here the shell #1 grind is the way to go), a 750cc kit (more displacement always helps), I am told a 2 into 1 exhaust helps a bit but I haven't tried it so can't confirm, better carbs (Mikuni vm34 or flat slides).

[@Peter57808]

Awesome, do you have the dimensions for the case stand , and or build instructions for the engine case stand?

[@2wheelworkshop]

I just kind of knocked it together around the engine from stuff I had lying around. I will take some measurements tomorrow and let you know.

[@Peter57808]

Ok thanks, will do the same

[@2wheelworkshop]

Sorry. I got sidetracked. The rear mount is a 240mm long peice of 100x50 RHS with the top cut into a channel and a 13mm hole drilled at 220mm from the base that mounts to the rear of the bottom case. The front mount is a 390mm high peice of 30x30 SHS hinged at 110mm from the base. It has a 75mm rectangular stirrup welded on the inside with a 13mm hole at 365mm from the base that mounts to the front of the top case. Linear distance between front and rear mounting holes is 330mm approx.(not critical due to the hinged front mount.

[@2wheelworkshop]

If I was to build it again I would do it very differently as I can't mount the engine with the starter mounted. It is by no means the ideal stand. Just something I through together out of junk I had on hand.

[@SondreForsell]

Hi mate! Quick question; can I start working on the top end, even though the clutch plates aren't mounted? I had to order a thruster plate. Will probably take two weeks before it arrive. I've done everything you've done in this video, except the clutch of course.

[@2wheelworkshop]

Yeah mate. Shouldn't be a problem

[@SondreForsell]

@@2wheelworkshop thanks again mate! I couldn't do this without your videos. I'll make sure to add a thank you on a future video, if you're ok with it. Btw lost the cam chain six times and forgot to put on a cam chain guide, below the tentioner. Had to fit the pistons three times also because of a wrongly placed gasket. It was frustrating, but I can probably put these parts together blindfolded now. Cheers from Norway!

[@sandmanGT350]

I would really like to tear mine down like that but if it ain't broke don't fix it right. Well I do need to address electric start issue. As soon as kicker gives me grief

[@sandmanGT350]

@@2wheelworkshop On its side!! Thats sacrilegious to me😭..😉 I've seen you video on that spring clip you adjust slightly. I will attempt it but it WILL be upright😀

[@sandmanGT350]

@@2wheelworkshop ya I was thinking about and I guess your right. I may try it . thks for tip

[@coconut-ve4zm]

At 10:09 you wrote to “install the half rings in their slots” but I only have one (1) half ring, am I missing one or was it a typo?

[@2wheelworkshop]

The output shaft has 2 half rings (to make 1 complete ring) on the large bearing, and from memory the input shaft has a locating split ring fixed on the bearing.

[@BudFox559]

How did you like the 5th over drive? Did it work ok?

[@2wheelworkshop]

I feel like I can't give an accurate review as I've had too many issues with 5th gear. Before and after the swap. If I were to do it again, I think I would just experiment with sprockets.

[@BudFox559]

@@2wheelworkshop Ok thanks, I am running a 32 rear sprocket and it works well, in most situations, but I have to slip the clutch a little more on take off. Gear problems can sometimes be a warped clutch disk dragging. I have had to deal with that when I first got it running again, after sitting for years

[@benvoiles3505]

Where do you get the overdrive gear?

[@2wheelworkshop]

I ordered mine from Geoff's XS in Australia.