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  • Home
  • Restorations
    • '78 Yamaha XS750 Special
    • '73 Kawasaki H1D Mach III
    • '73 Harley Sprint SS350
  • Harley-Davidson
    • 2018 Harley 883 Iron
    • 1979 Ironhead Sportster

1978 Yamaha XS750 Special Revival Series

XS750 Build Videos

XS750 Build Videos

XS750 Build Videos

Revived '78 XS750 Special

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

Watch Videos of the Build

Build Parts List

XS750 Build Videos

XS750 Build Videos

We documented almost all of the parts, lubricants, tools, setting and reference material to help you save time

See Build List

Awesome Vendors

XS750 Build Videos

Awesome Vendors

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.

Vendor Highlight

Video

Day 1 - Taking in the Basket Case

What have we done?!!! - Will this XS750 ever run again

Day 2 - How far did we get in 24 hours?

We uncover some promise, and the beginning of a long "To Do" list

XS750 Electrical Fixes

Getting the Electrical sorted early is critical for any vintage motorcycle revival. We share a few items on the list.

XS750 Total Brake Overhaul

We do a full brake down!!! Safety first, and getting 42 year old brakes to function properly takes a bit of work!

XS750 Stainless Brake Lines by Galfer

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

XS750 Gear Oil Change

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.

Polishing Rusted Chrome

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

XS750 Fork Oil Change

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 

XS750 Speedometer and Tachometer Repair

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

XS750 Steering Stem Bearing Lubrication

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.

XS750 Delkevic Stainless Steel Exhaust

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.

XS750 Terrible Modification by PO

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!

Video

Will it Start?!!!

After 22 days and countless hours do we have a running bike?

300 Mile Update

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.

Install of Re-Chromed Tail Light Bracket

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. 

Build List - Parts, Settings, Services

XS750 Parts / Vendors / Settings

1978 XS750 Special Revival

BRAKES:

Stainless Lines

https://galferusa.com/product/yamaha-1978-xs-750-special-front-lines-fk003d273-3

https://galferusa.com/product/yamaha-1978-xs-750-special-rear-lines-fk003d273r

Pads

Front Left

https://www.mikesxs.net/yamaha-brake-pads-left-hand-front-xj650-xs750-xv750-xs850-xv920-xs1100.html

Front Right

https://www.mikesxs.net/yamaha-xs650-front-brake-pads-xs400-sg-sh-80-81.html

Rear

https://www.mikesxs.net/xs650-parts/brakes/oem-type-rear-brakes-70-84/yamaha-xs650-brake-pad-set-2-77-84-front-rear-oem-1j3-20000-11-1j3-20000-13-3h5-w0045-00-2m0-w0046-01-4k0-w0045-00-1l9-w0046-00-2j2-w0046-00-3g1-w0046-00-3h5-w0045-00-1j3-w0046-00-1j3-w0045-00-1l9-w0045-00-1u4

Rear Master Cylinder Rebuild Kit

https://www.mikesxs.net/yamaha-xs650-master-cylinder-rebuild-kit-rear-78-80-oem-1j3-w0042-50-00-1j3-20000-50-2mo-25850-50-00.html

Front Calipers Rebuild Kit 

https://www.mikesxs.net/yamaha-xs650-brake-caliper-sealing-kit.html

Rear Master Cylinder Rebuild Kit

https://www.mikesxs.net/yamaha-xs650-brake-caliper-rebuild-kit-fr-r-77-84-oem-1j3-w0047-00-1j3-20000-20-00.html

Replacement Front Master Cylinder / Lever

https://www.mikesxs.net/yamaha-xs650-1mh-front-master-cyl-16mm-bore.html

Rear Brake Switch: ( the spring is too long and must be shortened to fit)

https://www.mikesxs.net/yamaha-xs650-stop-switch-rear-oem-353-82530-01-1j7-82530-01.html

ENGINE:

Engine Oil

https://www.jpcycles.com/product/510-1328/bel-ray-10w40-mc-4t-mineral-engine-oil-1-liter?redirectedKeyword=510-1328&totalResult=1

Oil Filter

https://www.mikesxs.net/yamaha-xs650-oil-filter-xs750-850-1100-oem-1j7-13441-10.html

Oil Filter O-Rings

https://www.mikesxs.net/yamaha-xs650-o-ring-for-xs750-850-1100-oil-filter.html

Fork Oil

https://www.jpcycles.com/product/544-846/bel-ray-high-performance-fork-oil?redirectedKeyword=544-846&totalResult=1

Air Filters

https://www.knfilters.com/rc-1200-universal-clamp-on-air-filter

Spark Plugs

https://www.jpcycles.com/product/zz43164/ngk-standard-spark-plug-bp7es?redirectedKeyword=ZZ43164&totalResult=1

Spark Plug Wires

https://www.ebay.com/itm/392802345049?ViewItem=&vxp=mtr&item=392802345049

Carburetor Rebuild Kit

https://www.ebay.com/itm/3-x-Carburetor-Carb-Rebuild-Kits-1978-1979-Xs750-3-Kit-18-2662/201577427587?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649

145 Main Jets (order 3, even though they show 4 are included)

https://www.jpcycles.com/product/403-211/ebc-145-mikuni-style-slot-head-jet?redirectedKeyword=403-211&totalResult=1

Fuel Mixture Screw – 2.5 Turns

Plastic Floats

https://www.mikesxs.net/yamaha-xs650-plastic-carb-float-34mm-cv-carbs-oem-256-14919-00-00-3h5-14985-00.html

Synch Set Up – (3) Glycerin Filled Vacuum gauges, ¼” barbed fittings,  and 3/16 heavy wall tubing

Petcocks

https://www.2fastmoto.com/Yamaha-Petcock-Fuel-Gas-Tap-Valve-Right-or-Left-XS650-XS750-Special-XS850-XS1100_p_954.html

Petcock Mounting 

M6-1x20mm Screws and Washers from Home Depot. Used a tight fitting O-Ring between washer and Tank

Exhaust

https://delkevic.com/full-system-to-fit-xs750s-1978-1979-xs850-special-1980-1982-with-classic-megaphone-muffler-and-stainless-steel-3-1-headers/

TIRES:

Font

https://www.jpcycles.com/product/214-055/dunlop-d404-100-90-19-front-tire?redirectedKeyword=214-055&totalResult=1

Rear

https://www.jpcycles.com/product/zz25309/dunlop-d404-110-90-18-rear-tire?redirectedKeyword=ZZ25309&totalResult=1

Valve Stems

https://www.jpcycles.com/product/903-712/bikemaster-chrome-tubeless-valve-stem?redirectedKeyword=903-712&totalResult=1

ELECTRICAL:

Starter Button

https://www.mikesxs.net/yamaha-xs650-button-with-spring-starter-horn-oem-27010-1009.html

Blade Fuse Box (too tall to fit in original location, moved it to toolbox. I am working on a better solution

https://www.summitracing.com/parts/HLA-H84960071

Regulator Rectifier

 https://ricksmotorsportelectrics.com/OEM-Style-Yamaha-Rectifier-Regulator-10_410 

Voltmeter

 https://www.ebay.com/itm/MINI-SMALL-3-DIGIT-RED-LED-2-WIRE-AUTORANGE-DIGITAL-PANEL-VOLTMETER-3-30V-USA/381997865508?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649 

TOOLS:

Tire Balancer

https://www.amazon.com/gp/product/B07JBZ2XH8/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

Tire Spoons and Rim Protectors (The protectors are a bit soft, and tore a little, rims were not damaged though)

https://www.amazon.com/gp/product/B07DCKJ1RB/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1

J.I.S. Screwdrivers

https://www.amazon.com/gp/product/B00A7WAHTU/ref=ppx_yo_dt_b_asin_title_o03_s00?ie=UTF8&psc=1

OTHER:

Mirrors

Left - https://www.mikesxs.net/yamaha-xs650-classic-cruiser-mirror-left-or-right.html

Right - https://www.mikesxs.net/yamaha-xs650-classic-cruiser-mirror-yamaha-rh.html

Seat Hinge Pins 

https://www.mikesxs.net/yamaha-xs650-seat-hinge-pin-set-2-for-standards-oem-91501-05055.html

Reference:

XS750 / XS850 Service Manual

http://biobug.org/motorcycle/xs850/Yamaha-XS70-XS850-Service-Manual.pdf

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, 

Awesome Vendors

Cedar Grove Motors LLC

Cedar Grove Motors LLC

Cedar Grove Motors LLC

Spark Plug Wire Assemblies for '78 XS750 with proper resistance

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.

Visit Their Ebay Store

MikesXS

Cedar Grove Motors LLC

Cedar Grove Motors LLC

Plastic float for XS750 Carburetor

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


Find out more

K&N Filters

Cedar Grove Motors LLC

Carburetor Rebuild Kits

K&N RC-1203 Air Filters for the XS750

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!!!

K&N Store

Carburetor Rebuild Kits

Carburetor Rebuild Kits

Carburetor Rebuild Kits

Carburetor Rebuild Kits for '78 XS750

These kits worked great the first time. Quality looks great, and worked as expected.

See on Ebay

Dunlop 404 Tires

Carburetor Rebuild Kits

Dunlop 404 Tires

Tubless Dunlop 404 Tires for '78 XS750 Special

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.

Purchase at J&P Cycles

Manual Petcocks

Carburetor Rebuild Kits

Dunlop 404 Tires

Manual petcocks for XS750

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

Purchase from 2FastMoto

Regulator / Rectifier

Regulator / Rectifier

Regulator / Rectifier

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!

Purchase from Rick's

Regulator / Rectifier

Regulator / Rectifier

Regulator / Rectifier

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

Contact Mazzoli's

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