Diesel's XS650

Dieselchanic · Aug 9, 2013

I edged my seat pan with door edge trim to keep it from cutting the vinyl.

Glued a small piece of foam to the rear part of the pan to take up the sharp angle there.

Covered the rest of the pan with foam and sanded it to shape.

Dieselchanic · Aug 9, 2013

Now this next part I'm gonna kinda skim over. I've only got one pic, the vinyl with the pleats laid out.

After that stuff got kinda hairy, actually I was positive it wasn't going to work. But a stopped clock gets it right twice a day...

It could be better but I'm happy with it for a first try.

Dieselchanic · Aug 9, 2013

Here's the seat on the bike.

Dieselchanic · Aug 19, 2013

I pulled my forks off and took off the headlight mounts and other garbage. Cleaned them up a bit then put on a new set of Daystar truck shock boots. Mounted up the clubmans like they're spose to be. I like them. Mounted my headlight, which was a freebie sent to me by a bro(cool), but I hate it. Love the light but hate how I mounted it. Needs to go up and back. Alot. Mounted my taillight and license plate too.

Dieselchanic · Aug 19, 2013

Started on my rear fender. Took two xs fronts and sliced them then welded it all back together to make a bit wider fender. I think it's going to work.

Dieselchanic · Aug 26, 2013

I took the wiring harness that came on the bike and tried to decipher it. I narrowed it down to stuff I could use and ended up with this.

I cleaned it up turning it into this.

Then I put together the rest of my harness basing it off of a 6 gang fuse block. I still need to run some inline fuses coming from the battery and make the main switch harness.

If you guys see something that won't work or is wrong let me know.

Dieselchanic · Aug 28, 2013

Trying the Metal Rescue on my tank. It only has surface rust so I have high hopes.

Dieselchanic · Aug 30, 2013

Took to my frame with the grinder. It's amazing how much metal you take off!!

Took out the motor mount support tube and cleaned up the neck area. I plan to gusset the neck. I know some people run them like this and while it looks good I just can't make myself leave it like that...

Also cleaned up the frame under the seat area and cut the shock mounts off.

Here is how I left it last night. Ready to start welding on it again...

scabber · Aug 30, 2013

Like your bike and your really build it yourself way of thinking. The frame rails look professional. Same goes for the seat it fits and looks great. Nice work on the bender. Like it all. :thumbsup:

Dieselchanic · Aug 30, 2013

scabber said:
Like your bike and your really build it yourself way of thinking. The frame rails look professional. Same goes for the seat it fits and looks great. Nice work on the bender. Like it all.

Thanks. I'm broke.. Doing it myself is the only option.

Dieselchanic · Aug 30, 2013

Got the shock mounts back on on one side... Looking a little closer to what I had in mind...

scabber · Aug 31, 2013

Dieselchanic said:
Thanks. I'm broke.. Doing it myself is the only option.

I'm broke with you watching with interest.

Dieselchanic · Aug 31, 2013

I finished up the rest of my wiring harness by adding an inline fuse to the charge wire and made a main power wire harness coming from the battery, with inline fuse, going to a 40 amp relay. My bar switch will operate this relay... So now I've got 10 awg wire from the battery, running thru a 40 amp relay, I need to put in a 30 amp fuse but a 20 was the highest I had laying around... my fuse holders are rated to 30 amps, so with this setup I should have adequate power I should think?

Here's a vid of me testing it... Crap quality but o well. The wires I've got connected to the fuse block are the headlight/taillight wires which share a common ground run directly to the power source. It might be kind of hard to decipher everything else going on. My bar switch is just temporarily wired.

And I was in the house so you can just ignore the family.....

This was my first wiring harness build and I enjoyed it very much. I have known the basics of wiring for years from working on my old big trucks but learning all the fuse and amp ratings and layout was interesting. Also with my final setup with the main switch and relay.. Got something up my sleeve on that yet

Nomadic · Aug 31, 2013

Looks good, you should be fine with that if you switch the 20 to a 30 like you said. Are you using all 6 ccts?
Nice to see you doing it all yourself.

Dieselchanic · Aug 31, 2013

Nomadic said:
Looks good, you should be fine with that if you switch the 20 to a 30 like you said. Are you using all 6 ccts?
Nice to see you doing it all yourself.

Only 4 circuits. The two on the bottom right in the top pic will be spares. I've got headlight, taillight, coils, and brake light. Each to its own circuit is overkill amp draw wise, but I did it for redundancy. As far as that goes the whole mess is overkill seeing as how the whole bike will probably see less than a 10 amp draw altogether...

Btw this is a VERY simple harness. As far as requirements in Alabama I know you're supposed to have a horn but I don't think turn signals are mandatory. Since its already registered and I'll likely never get checked I'm not worried about it.

Nomadic · Sep 1, 2013

Yeah horns are for sissys.

As for sigs, who actually uses them any more anyway? Where I live, it's about 50% whether or not cagers use them and besides, if you ride like your invisible anyway, you'll be good.
Let the safety people freak out now... But if you need em to pass a registration then there's nothing you can do about that.
I more often than not omit sigs on my bikes. Anytime I have the FBI in pursuit behind me, I'm always sure to use hand sigs and never had a problem.

I like your harness. I like to put the components in place then run the wiring, but your barebones set up is definately the way to go on your bike. Love it.

Conrad Russell · Sep 1, 2013

Diesel,great thread I've been watching the build and it looks like your heading toward a bike you can be very proud of! :thumbsup:

Sn34ky · Sep 3, 2013

Keep going man! I really like your seat rails/seat setup!

Dieselchanic · Sep 3, 2013

I need to get busy and finish it. I'm so close.... But it's less than a month before our little girl arrives and the wife is standing over me with a stick while I try to get a nursery set up.... For some reason the bike isn't a priority to her

scabber · Sep 3, 2013

Congratulations on the pending birth. I got used to being broke after my daughter was born.

Nice progress on the bike. Wiring looks great no signals no problem if not required. The nursery is real important to expecting mothers get er done. :thumbsup:

Diesel's XS650

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