Restoration of Yamaha XS 650 special - Introduction

The project that the grade 12 tech class is working on this year, is the restoration of a 1978 Yamaha XS 650 special bike. The bike was donated to the school by a parent of a student who wanted to give us a challenge.

The frame and suspension of the bike is in surprisingly good condition, which is interesting based on the fact that it has been sitting in a barn for many years. There is some rust and dirt on the front fender, suspension, brake components, and handlebars. Sunjin and Alec will be focusing on removing the rust, and taking care of the look of the bike.

The problems with the bike are extensive. The only problem concerning the engine at this point, is that both pistons are seized within the cylinders. Eric and Steffen are dismantling the engine to get to the problem and looking for other problems along the way.

Other problems with the bike include rusted electrical fuses and components, dead battery, seized brake calipers, broken ignition switch and brakes must be serviced. I will primarily be working on the electrical (i.e. replacing battery, cleaning and servicing wires and brake components) and once completed will move on to the brakes and suspension. 

Today, Eric and Steffen removed the gas tank mounting bolts. The gas tank is about ready to come off. Sunjin also took off the exhaust.