Boorrrringggg Build/Rebuild/Refres&restore

[3Phase]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

The gasket looks a little ragged but at least comes with four cam plugs for your twenty bucks so there're a couple of spares.

I'm the guy with the locked up oil filter bolt.

Right. If they are that tight and they do get mangled but you get them out without ripping out the aluminum threads, get some new bolts. Here's a good looking set from a Midnight Special and it has the throttle cable bracket too for about $9 plus $6 for Expedited shipping:-
http://www.ebay.com/itm/80-YAMAHA-XS.../380884485516?

If the bolts are overtightened, the aluminum will start to lift up around the holes where the bolt threads started to pull out of the head. That makes little raised spots that'll cut into the gasket when it's tightened or just keep the cover from sitting flush on the head.

Before you put the valve cover back on, use a hammer with some round stock to carefully knock the aluminum back down around the bolt holes, then use a tap (best) or one of the bolts to clean up the threads.

Aww, Phil. I was just about to buy a roll of gasket and start razoring.

Seriously, thanks.

Heh, razors are dangerous, man, and the valve cover gasket is skinny and it's easy to tear it up. Use a good pair of sharp scissors like cuticle scissors and stay away from the ones in the wife's sewing kit.

For sealing the cam plugs, use Yamabond 4 or ThreeBond 1194.

[motoman]

The half-moon cam plugs I highly recommend using Hi-Temp Grey silicone sealer, not just any ole' RTV.

[bikerphil]

Yep, I find that if you are using RTV sealer instead of a gasket, you need to be 100% perfect installing the cover or you risk having a leak. There is not much room with the engine in the frame to finagle the cover in place. Use RTV on the half moon cam plugs though.

[puskrat]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

http://www.ebay.com/itm/YAMAHA-1978-...NS4vs~&vxp=mtr

Aww, Phil. I was just about to buy a roll of gasket and start razoring.

Seriously, thanks.

[puskrat]

You shouldn't mess up any bolts unless someone went crazy on them

I'm the guy with the locked up oil filter bolt.

[bikerphil]

I would recommend using a gasket, this kit has the cam end plugs you will also need...

http://www.ebay.com/itm/YAMAHA-1978-...NS4vs~&vxp=mtr

[3Phase]

... How likely am I to consume head cover bolts during this process, and what other than a gasket should I order before I start disassembling?

You shouldn't mess up any bolts unless someone went crazy on them, the torque's only supposed to be 1 m/kg or 7.2 ft/lb (86.4 in/lb).

Gaskets are spendy. You can use Permatex The Right Stuff or something similar to seal the cover or you can buy a gasket, it's up to you.

I keep the Yamaha gasket on a shelf with some other gaskets to use as a template. Trace the gasket on a roll of gasket material from the parts store, cut it out and punch the holes with a hole punch.

What's my next routine task?

Proceed to tidy up with care.

Is it cam chain tensioner time?

Like Frank said, you might as well while the valve cover's off.
Put the bike on the center stand before you try to adjust the chain tension so it doesn't droop down and fall off to one side of the gear on the crankshaft. If that happens, it'll seem to adjust and tighten the chain but since it's not really on the crank sprocket you'll destroy the valves when you turn the crankshaft and the camshafts don't turn with it.

[FranksBMW]

May as well do the cam chain tensioner while you wait for valve cover gasket (if you're ordering). Place bike on centre stand is what I've read to be important.

[puskrat]

Okay so I've gathered from my reading the first thing I need to do after refreshing my carbs is adjust my valves. How likely am I to consume head cover bolts during this process, and what other than a gasket should I order before I start disassembling? What's my next routine task? Is it cam chain tensioner time?

[puskrat]

grabbed a "handi pak" of 4mm flatheads which turned out to be too long. bent the badge mounting tabs on the tank in the process of learning of the length fail. used some leftover fuel line to run my overflow drain to earth. Need to run next door for a can full of iso octane, adjust my battery clamping mount, and I think I can start doing things like checking coils rectifiers and alternators, and tearing through the bird's nest of wiring formerly hidden behind my fairing. OH and evaluating my previous carb work and petcock installs. Still not sure if the Venturer fairing goes back in or if a windshield replaces it, and with or without windshield, what happens with the rectangular headlight in my parts pile.

[puskrat]

XS11.com | Tank emblem screws

youre a lifesaver

[3Phase]

XS11.com | Tank emblem screws

They are M4 x 0.7

Total length 6.3mm, 4mm threaded

[puskrat]

here we go: Does anyone have a clue what size these jolly tank badge mounting screws are? I picked up two pair of 3mm flat socket heads. That is the wrong size.

[motoman]

WHEW. thanks guys. When I saw it referenced today in a Youtube vid, it dawned on me I'd seen/read/heard conversation about overflows (besides the tank) but not seen anything in our discussions on the site or in my manuals or parts blowups. Thanks again for the tips. i'd hate to do this whole carb rebuild, petcock replacement, etc to stop fuel from getting into my oil then end up losing to this.

Most welcome......also, ask your questions on here, from real professionals, and avoid that You-Tube nonsense. It'll just lead you down that perverbial 'rabbit hole'.

BTW, we don't mind any question you may have. We definitely don't think someone is stupid for asking. Only stupidity...... is questions NOT asked!

[puskrat]

WHEW. thanks guys. When I saw it referenced today in a Youtube vid, it dawned on me I'd seen/read/heard conversation about overflows (besides the tank) but not seen anything in our discussions on the site or in my manuals or parts blowups. Thanks again for the tips. i'd hate to do this whole carb rebuild, petcock replacement, etc to stop fuel from getting into my oil then end up losing to this.