We tried to document the process, and give you some insight on what it took to get the XS750 back on the road. We hope you enjoy these videos
We documented almost all of the parts, lubricants, tools, setting and reference material to help you save time
Reviving a motorcycle from the 70's takes dedicated vendors, and thankfully there are folks who are passionate about what they do. We share more details here.
What have we done?!!! - Will this XS750 ever run again
We uncover some promise, and the beginning of a long "To Do" list
Getting the Electrical sorted early is critical for any vintage motorcycle revival. We share a few items on the list.
We do a full brake down!!! Safety first, and getting 42 year old brakes to function properly takes a bit of work!
Rubber brake lines feel spongy and there is no place on this build for poor brakes. We show you how to get Galfer Stainless Steel Lines installed
Getting the gear oil drained and replaced is a bit tricky on a bike this old, we show you how to avoid doing any damage to the delicate aluminum housings.
Have rusted and ugly chrome hardware and accessories, look no further! We show you how to restore the finish quickly and easily with stuff you already have at home
It can be tricky getting into the forks on the XS750, we show you how to get them open safely and replace the fork oil
We replace the broken lens on the Tachometer, it is a delicate operation and hopefully our tips help you get your's looking new too
Even if you don't have any problems now, old bike usually have no grease left in the bearings. We open up the steering stem, clean and inspect the bearings before lubricating and reassembly.
The exhaust was destroyed by the previous owner, so after being satisfied with the project progress we dive into a full replacement of the exhaust system.
This poor bike never had a chance to run properly once it was torn into by the PO. Luckily they stopped before doing any more harm. We show you a few gems!
After 22 days and countless hours do we have a running bike?
The XS750 had a pretty challenging issue pop up with the charging system. After a lot of testing and some really good advice from the FB Group, we found a broken wire feeding the system power to the Field Coil. The bike has been out on several short trips followed by a 166 mile excursion along the Hudson River. Hear a review of the work done, start up and road footage from the trip.
The tail light bracket on the '78 XS750 was chewed up with rust, far beyond the foil and saltwater trick. We sent it to Mazzoli's Sales and Service in Cicero, NY for a proper re-chrome.
1978 XS750 Special Revival
Rear Master Cylinder Rebuild Kit
Front Calipers Rebuild Kit
Rear Master Cylinder Rebuild Kit
Replacement Front Master Cylinder / Lever
Rear Brake Switch: ( the spring is too long and must be shortened to fit)
Oil Filter O-Rings
Spark Plug Wires
Carburetor Rebuild Kit
145 Main Jets (order 3, even though they show 4 are included)
Fuel Mixture Screw – 2.5 Turns
Synch Set Up – (3) Glycerin Filled Vacuum gauges, ¼” barbed fittings, and 3/16 heavy wall tubing
M6-1x20mm Screws and Washers from Home Depot. Used a tight fitting O-Ring between washer and Tank
Blade Fuse Box (too tall to fit in original location, moved it to toolbox. I am working on a better solution
Tire Spoons and Rim Protectors (The protectors are a bit soft, and tore a little, rims were not damaged though)
Seat Hinge Pins
XS750 / XS850 Service Manual
Services not listed above:
Lubrication: Tachometer Drive, Speedometer and Tachometer Cables, Clutch Cable, Steering Stem Bearings, Rear Wheel Splines
Electrical: Cleaned all grounds and switch contacts verify no resistance with multimeter
Adjustment: Clutch Rod, Clutch Cable Free Play, Cam Chain Tension
Repairs: Speedometer Face, Tachometer Lens,
The Original Resistance Spark Plug Wire Assemblies typically fail, when replacing you need to make sure they are with in 100ohms of each other. Cedar Grove include QC data with each set so you know they are perfect.
They have almost everything you need to fix up your XS750. All of our brake rebuild kits came from Mikes, and a whole lot more! Our favorite upgrade was the Plastic Carburetor floats
Our bike didn't have the original air box, and the filters installed had a inner lip that would obstruct air flow. We decided on K&N because of quality. Followed their Jetting guide and got it right the first try!!!
These kits worked great the first time. Quality looks great, and worked as expected.
We were successful installing tubless Dunlop 404s on the XS750, we went with stock size which is a very narrow 110 in the rear!!! Handles great though.
We wanted manual petcocks, no silly diaphragms. These worked great, but you need to supply your own M6-1x20mm bolts and seals to install them on the tank
Rick's is a great business and is responsible for keeping the electrical working on countless classic motorcycles. They make a superior product and stand behind it!
Mazzoli's Sales and Service provides incredibly fast and high quality services like re-chroming. Reach out to Bob on FB: https://www.facebook.com/Mazzolis-Sales-Service-2013-494557310592800
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