23/07/2013
Keeping Your Classic Yamaha XS650 on the Road
The Yamaha XS650 is a true icon in the world of classic motorcycles. Renowned for its torquey parallel-twin engine and robust build, these bikes continue to capture the hearts of riders and customisers alike. However, like any classic machine, maintaining an XS650 often requires a keen eye for sourcing quality parts and understanding the nuances of its engineering. Whether you're embarking on a full restoration, a custom build, or simply need to replace worn components, knowing where to find the right parts is crucial. This article will guide you through the essential aspects of keeping your beloved Yamaha XS650 in top condition, with a particular focus on readily available parts and a significant performance upgrade: the rephasing of its crankshaft and camshaft.
Where to Source Your Yamaha XS650 Parts
Finding parts for classic motorcycles can sometimes feel like a treasure hunt. Fortunately, for the popular Yamaha XS650, there are dedicated suppliers who understand the needs of these machines. One such reputable source is Old Bike Barn. They offer a comprehensive selection of parts designed to help you resurrect and maintain your Yamaha XS650. You can expect to find everything from essential engine gasket sets and carburetor kits to crucial wear items like fork seals, levers, cables, and brake pads. Having a reliable supplier like Old Bike Barn ensures that you can source the necessary components without compromising on quality, allowing you to get back on the road or finish that project with confidence.
Understanding the "277" Rephasing Service
Beyond routine maintenance, many XS650 enthusiasts seek to unlock even more performance from their parallel-twin engines. A highly regarded modification that significantly enhances the bike's character and power delivery is the rephasing of the crankshaft and camshaft. This process, often referred to as the "277" modification, involves precisely altering the timing of the engine's internal components to optimise combustion and power output. Hugh's HandBuilt is a leading name in this specialised service, having pioneered and refined the process since the early days of XS650 customisation. Their expertise in rephasing is what initially put them on the map, alongside their innovative PMA (Permanent Magnet Alternator) Systems.
Why Rephase Your XS650 Crankshaft and Camshaft?
The standard XS650 camshaft and crankshaft are designed for general usability and reliability. However, by rephasing them, you can achieve a more aggressive and potent engine character. The "277" designation typically refers to a specific crank configuration that, when paired with a similarly rephased camshaft, results in a noticeable increase in low-end torque and a broader, more engaging powerband. This modification is particularly favoured by riders who want their XS650 to feel more responsive and powerful, especially in everyday riding scenarios. The benefits include:
- Improved Torque: A significant boost in low to mid-range torque, making acceleration more spirited.
- Broader Powerband: The engine pulls harder across a wider RPM range.
- Enhanced Engine Character: A more distinctive and engaging sound and feel from the parallel-twin.
- Durability: When performed by experts like Hugh's HandBuilt, the process includes strengthening critical components for high-RPM reliability.
For a deeper understanding of the benefits and the technicalities of rephasing, resources like the linked articles provide excellent insights into the "277 Rephased Goodness" and the advantages of this modification.
The "277" Crank Rebuild Process
The rephasing of the crankshaft is a meticulous process that requires complete disassembly and expert rebuilding. Here's a breakdown of what you can expect:
- Complete Disassembly: The crankshaft is taken apart down to its individual components, including every needle bearing, rod pin, and flywheel.
- Inspection and Cleaning: Each part is thoroughly cleaned and inspected for wear or damage. This allows for an accurate assessment of the crank's condition and whether any components need replacement.
- Component Sourcing: If your crank requires new parts, Hugh's HandBuilt will contact you to discuss the necessary components, offering them at their cost price.
- Rebuild and Truing: Once all components are in good order, the crank is rebuilt from the centre outwards. Bearing surfaces are polished, bearings are cleaned and oiled, and flywheels are deburred.
- Welding for Durability: For enhanced reliability at higher RPMs, each pressed joint in the rebuilt crank is meticulously trued and then TIG welded.
- Final Truing and Welding: After the rods and outer flywheels are installed, the entire assembly is trued in specialised fixtures. A final TIG weld is applied to each end of the rod pins, ensuring maximum reliability and performance. The result is a crank that is ready to be bolted in, performing as well as, if not better than, an OEM unit.
The "277" Camshaft Rephasing Process
Similarly, the camshaft rephasing is handled entirely in-house to ensure precision and quality:
- Inspection: The camshaft is thoroughly inspected for wear on the lobes, bearing surfaces, and the advance unit pin location.
- Machining and Rephasing: Provided the camshaft is in good condition, it is then machined and rephased on specialised fixtures to precisely match your rephased crankshaft.
- Cam Gear Installation: The camshaft is returned with the cam gear already installed, making it a direct bolt-in component for your engine.
- Compatibility: Hugh's HandBuilt can rephase any OEM or reground camshaft. For performance regrinds, they recommend Gary Hoos at Hoosracing.com.
Important Note: It is not possible to rephase MikesXS "Billet" camshafts, as their material composition does not lend itself to the necessary machining and welding processes.
The "277" Ignition System Options
Complementing the rephased crank and cam is an appropriate ignition system. Dan at Pandemonium Customs offers a highly recommended "277 Ignition System." These systems are designed by riders for riders, ensuring real-world testing and reliability. You have two main options:
- Pandemonium 277 Ignition: This is often the preferred choice, especially when paired with a mechanical advance. It works exceptionally well in conjunction with Hugh's HandBuilt PMA Charging Systems, allowing for batteryless operation or the use of a battery, as desired.
- Modified Points Ignition: Alternatively, you can modify an existing points ignition system to work with the rephased crank and cam.
The correct ignition timing is paramount for the optimal performance of the rephased components.
Installing the "277" Package
One of the great advantages of the "277" modification is its compatibility with many existing engine components. You can use any aftermarket or OEM pistons and camshaft profiles just as you would with a standard XS650 engine. The primary changes are to the ignition system, crankshaft, and camshaft. Timing the engine is straightforward, focusing on the #1 Cylinder (the alternator side, or left side when sitting on the bike). Crucially, all original timing marks on the crankshaft and camshaft are retained, simplifying the rebuilding process. Hundreds of owners have successfully performed this modification at home using basic hand tools and the provided rephased components. For those who encounter difficulties, expert assistance is just an email away.
Labor Rates and Shipping
For those considering the rephasing service, understanding the costs involved is important:
| Service | Labor Cost | Notes |
|---|---|---|
| Crankshaft Rephasing & Rebuild | $475 | Excludes cost of any necessary replacement parts. Parts are offered at cost. |
| Camshaft Rephasing | $285 | Includes installation of cam gear. |
| Return Shipping (Continental US) | $65 (Flat Rate) | For both crank and cam. |
| Return Shipping (Cam Only) | $24 | |
| International Shipping | Contact for Quote |
Payment Note: All listed service prices are based on cash, check, or money order payments. A 4% fee will be applied to PayPal transactions.
How to Ship Your Components
To utilise the rephasing services, follow these simple shipping instructions:
- Packaging: Securely package your crankshaft and camshaft.
- Shipping Address: Send your package to the address provided on the Contact Page.
- Payment and Information: Include a check, money order, or cash for the service and return shipping, payable to "Hugh’s HandBuilt". Crucially, include a note inside the package with your full contact information: Name, Email Address, Postal Address, and Phone Number. Also, specify the services you are requesting.
- Component Inquiries: If any components are found to be necessary during the rebuild, Hugh's HandBuilt will contact you for approval and issue a separate invoice for those parts.
A Word on Crankshaft Failures
The text also highlights the importance of properly built and welded XS650 cranks, implicitly referencing potential failures in poorly executed builds. This underscores the value of professional services that employ robust welding techniques, such as TIG welding, to ensure the longevity and safety of the rephased components, especially under demanding riding conditions.
Frequently Asked Questions
Q1: Where can I buy general parts for my Yamaha XS650?
A1: Reputable suppliers like Old Bike Barn offer a wide range of parts, including gasket sets, carburetor kits, seals, levers, cables, and brake pads.
Q2: What is the "277" modification for an XS650?
A2: It refers to the rephasing of the crankshaft and camshaft to a specific configuration that enhances torque and broadens the powerband, resulting in a more engaging riding experience.
Q3: Can I rephase my own camshaft?
A3: While possible with specialised knowledge and equipment, it's a complex process. Professional services like Hugh's HandBuilt ensure precision and quality, including necessary inspections and welding.
Q4: What is the cost of rephasing a crankshaft and camshaft?
A4: Crankshaft labor is $475, and camshaft labor is $285. These prices do not include the cost of any replacement parts needed during the rebuild. Return shipping within the continental US is an additional $65.
Q5: Can MikesXS "Billet" camshafts be rephased?
A5: No, unfortunately, the material used in MikesXS "Billet" camshafts is not suitable for the rephasing and welding process.
By understanding your parts sourcing options and the significant performance benefits of services like crankshaft and camshaft rephasing, you can ensure your Yamaha XS650 remains a thrilling and reliable machine for years to come. Whether you're performing routine maintenance or undertaking a performance upgrade, investing in quality parts and expert services is key to preserving the legacy of this classic motorcycle.
If you want to read more articles similar to Revitalise Your Yamaha XS650: Parts & Performance, you can visit the Motorcycles category.