RonXS' Build Thread - The Soft Cafe

The bike reminds me of the RD400 so much... Thinking I'll put RD650 decals on the side covers.

As the photo of your bike scrolled onto my screen as soon as the top of the tank I immediately thought of my beloved 78 RD400. My next 650 I'm copying you.
 
A big shout out to ThatXS650Guy! A spacer & shim care package arrived to setup the XS500 wheel. Thanks Jim!

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Remember where I said the my RD400 was the Rocket... Well 'ROCKET' wont fit on a motorcycle license plate. I don't have the plate any longer, but I still have this...
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Spent most of the day fixing the threads on the passenger peg nut. It was so tight (not from rust) that the acorn nut would not budge. Threads were damaged when I finally got it free. Didn't have a 12 x 1.0 die... I really like being on my back chasing threads with a needle file. :mad:
 
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get yourself a square thread file with multiple thread pitches on it. you deserve it. once you use it once, you'll kick yourself in the ass several times for not getting one years ago.

don't trim that beautiful cowl, space it up a 1/4-1/2". Someday you might want to use different turn signals.....
 
What you need are some original Standard rear turn signal mounting brackets. They attached to the fender mount and would move your signals down and back some .....

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There's plenty of those brackets around if you are willing to straighten and derust.
I think all standards 74-79 used them.
 
Remember where I said the my RD400 was the Rocket... Well 'ROCKET' wont fit on a motorcycle license plate. I don't have the plate any longer, but I still have this...
2kyHbgP.jpg


Spent most of the day fixing the threads on the passenger peg nut. It was so tight (not from rust) that the acorn nut would not budge. Threads were damaged when I finally got it free. Didn't have a 12 x 1.0 die... I really like being on my back chasing threads with a needle file. :mad:

FWIW, I'm pretty sure the thread is 10x1.25. On most, if not all, Japanese bikes and cars, M8, M10 and M12 all have the same 1.25 mm pitch.
10x1.0 is something I would expect on German made stuff.
 
I just may have a set..
I'm betting Ron is not going to go for the bracket & exposed wire look ? Im gonna add a couple pics here showing which mounting components worked for me. The stalks cannot protrude far at all past the fender interior to avoid tire rubbing. Longer shocks do of course help there too. I used very narrow nuts, fender washers, and barely long enough stalks and "liquid rubber" to both help water proof and glue the thru wires. Attempting to prevent wire damage.
-R
 

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It's very possible eliminating the rubber mounts could cause issues. I did that when mounting stock signals to a saddlebag mount and it wasn't too long before they broke off. That 8mm TS stud isn't very big.
 
Thanks for all the input... I appreciate it. :thumbsup:

I've ordered a metric thread file. It's obvious that's a tool I should have in my toolbox.

The seat cowl shown belongs to another project. I'll need to source another or make one for the RD650 project. If making one, I'll copy the original but allow clearance for the turn signals. In the mean time, I'm checking Ebay for a used cowl. :)

The passenger foot pegs mounts are M12 x 1.25. Good catch. :thumbsup:

I tried moving the gas cap from the '78 XS to the '77 RD tank. It looks like it should fit, but it doesn't latch. The latch on the cap appears to be short 1/8". Are the XS Special caps different from the Standard?
 
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