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It started with buying a $1,000 1984 XS650K that was stock except for the handlebars. It was showing 37,000 Kms., the compression was 150/150 and I drove it enough to know that the motor and transmission were solid, but it leaked some oil and needed a clutch. After lurking here quite a bit and figuring out what I wanted, I stripped down the XS650 to the frame and started building a street/dirt/hooligan/brat/tracker. I’m not quite sure how to categorize this but, in a nutshell what I did was:


Engine:

ü 2-1 intake manifold and jetted Mikuni VM36 (from Joewiseguy, great to deal with).

ü 2-1 Chrome XS Performance Headpipe Set

ü Headpipe Torque Inserts

ü Free flowing Taper Tip Muffler

ü Kevlar clutch with high performance springs and one pushrod, changed the bearings, bushing and seal

ü Starter delete using a frost plug (whoever came up with that ... what a great idea!)

ü New oil filters

ü New seals and gaskets everywhere I could without splitting the case

ü Engine painted with VHT barrel paint

ü Side covers stripped, polished and clear coated with VHT clear coat.

ü High output coil, wires, plugs


Frame:

ü Thruxton 14.4”rear shocks, (and a delrin chain guide on swingarm)

ü Brass swing arm bushings and new seals

ü New wheel bearings

ü Seat hoop and seat from SCO Kustoms

ü Home made electric and battery box

ü Center stand and brackets removed, some other frame cleanup

ü Frame painted with VHT roll bar and chassis paint.

ü Simplified ignition and charging wiring harness from TC Bros., homemade wiring for everything else

ü Fork brace from Hugh’s Handbuilt

ü Fork boots

ü Magura 314 throttle

ü Simplified the hand controls

ü Mini speedometer

ü Changed the lights and signals

ü Tank cleaned, sealed, de-badged and painted, new petcock.

ü Forks and rear brake drum stripped, polished and coated with VHT clear coat.



Once I had reassembled it all it roared to life after a couple of kicks. Couldn’t sound better .... took her out for a 30Km exhilarating ride, it runs like a scared cat. Tons of revs and power, handles as well as I could have hoped, although I haven’t tried crossing a mud bog (yet). I had read on dimecitycycles.com ....

“Riding one of these old bikes can be a lot like getting in the ring with a bare-knuckle gypsy. In the beginning it seems like a good idea. He's small and wiry, looks to be somewhat tattered and should be easy to handle. That is, until he unleashes a hell bent whiskey fueled fury on your face and knocks your teeth out..”


Sounds good to me .... I’ll try to keep my teeth though ....
 
Wow...bike looks SWEET!!! Nice work.

Single carb, eh? Any issues with the far (right) cylinder don't getting as much fuel as the other?
If you're going to be riding trails, you may consider adding some type of front/rear fender... it's gonna get a bit dirty and little rocks hitting your knees doesn't feel good after a while. :)

Regardless...love it.
 
Thanks Brassneck,
I may end up putting a small front fender on, if I can find something that suits it. I'm ok with getting dirty but you're right ...sticks and stones may break my bones. No carb issues at all, thing between that and the exhaust it's a HUGE performance improvement.
 
Hi all its been a long time but have done some bits on my XS between mum getting ill grandchildren being born and extending my home. hope you are all well
 
Hi, I've had quite a few RDs, but this is my first XS. An old friend had it in his shed for about 20 years and realized he was never going to get it finished, so
he offered it to me. I normally restore 50s & 60s British bikes and this was a treat to restore.
I thought about modifying it, but its just too nice.
I completely striped it down, repainted the frame with 2-part epoxy, had all the hardware re-cad plated, and just polished up the chrome.
The paint was nice enough to touch up and polish. I just refreshed the motor with new rings and gaskets & seals.
It has the feel of a 70s triumph Bonneville, without all the drama.
XS650 docks.JPG
 
I picked up this bike for $200. I am planning on turning it into a Tracker style bike
 

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Pulled out my Low Mileage 79 XS650SF to take to the Australian XS650 Club AGM in Sydney where the bike was judged best bike at the event.
This bike has only done 1370 miles was only registered for one year as indicated on the sticker on the fork leg. The bike was only ridden for the one year (1979) then it sat in the guys bedroom covered until he passed away in 2013.
I imported it into Australia in 2014 where it was detailed and prepped to be put into storage.
A tank of gas, battery fitted and it fired into life on the second kick. Bike is like brand new and looks the part of that era.

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