Just another first build.

No soldering yet Captain Fun. I want to run the bike and make sure everything is 100% good to go.

Speaking of which, for a first start up after a rebuild, what's everyone's procedure?

I know I have spark already. I have the Pamco rotor set in the middle of the retard and advanced position. Cam chain tension is adjusted. Valves adjusted. I'd like to check for oil pressure on start up as well. Since I'm not using a tach; what's the best way to do this? I was thinking about cracking the fitting on the oil feed line where it connects to the reducer in the case and see if oil leaks out there. Then snug it back up once I see oil.

Should I run a fan in front of the engine as well?

Hoping to get her fired up by the end of this week!
 
Ah yes, very smart grasshopper. Sorry I can't help with start up procedure. I've never done a re-build before but I will soon enough. Good luck and keep those videos coming.
 
Some more pictures from Saturday.

With only the brake siwtches left, here is what the electronics pan looks like. Trying to keep it as neat and organized as possible, but it looks like spaghetti :laugh:

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Heat shrink over the neutral light so the connections don't get dirty, etc.

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I re-did the wire to the coil with a different route so I could put the loom up a little higher on the frame. Also put heat shrink on the connector.

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Turn signal wires with heat shrink. Running them through the frame took A LOT of patience!

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What the mess of wires looks like exiting underneath the tank :shrug:

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I spent some time away from the 650 today, to remind myself how I fell in love with motorcycles in the first place.

Helmet camera from some motocross fun today.

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I'll be spending this week figuring out what is up with my rear wheel. I really don't want to have to go back to spoked wheels if I can't figure out what's going on
nice whip no moto yet for me 12" of snow tonight
 
Ahh! For a second I didn't think there were any moto enthusiats on here. Thanks yammamun, hopefully you get to get out there soon :bike:
 
Some more parts showed up. Here's where I'm at after today.


Installed the tach drive plug.

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Sending the cap out to get powder coated black. I also sent out a 32T rear sprocket and kickstand out to get powder coated as well. (see video at the bottom of the page in regards to kickstand)

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New upper bolt for the triple trees. The original one had there had some blemishes that bothered me.

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Finally got the rubbers for the footpegs.

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Passenger pegs mounted.

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I also got rubbers for the kickstarter and shifter, but it looks like I ordered, or was given, the wrong ones. Shall look into that tomorrow.

This is what I'm using for the throttle cable. From Mikes. It barely catches the cable, but the cable is snug into the housing. :thumbsup: Thaank you guys for all of the suggestions

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I decided to powdercoat the float bowls after all :laugh:

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I have two sets of carbs, 4 bowls. Two of the bowls appear to be different fromthe other 2. There's a brass "post" in one of the types of bowls. Are these bowls interchangeable? Everything else about them looks to be identical.

The one with the post I'm talking about is on the right.

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Cut a little piece of cardboard to 24.3mm, and adjusted the floats.

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Also picked up some jets. The mains I got are identical to the ones that were in there. The pilots however appear to be slightly different in that there are little holes in the side of the jet. Still acceptable?

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I went from a 127.5 to a 130 on the pilot, and from 135 to 140 on the mains.

Can I adjust the needle height on these?

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And if so how do I get my snap ring pliers in there for the circlip? :laugh:

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Here's a ltitle video with the kickstand. Just trying to figure out if thet bike is leaning enough, or if it needs to lean more. It feels really sturdy with the stand at this length. Unless someone blatatnly walks into it pretty hard, or I try to use it on an uphill (which is a given) I don't think there will be any problems. What do you guys think?


I'm not sure if I recall telling you guys this, but I checked the advance mechanism for correct operation a week or two ago. I found that the weights weren't snapping back. I dissablemed the advance mechanism and removed the shaft. Wiped off the grease I used. Reassembled. Weights snapped back perfectly. Dissaembled again. Reassembled with white litium grease. Weights snap back perfectly. Just thought I'd give others a heads up not to use a grease that's too thick. Those springs are tiny and don't have a lot of force behind them.

Added gas to the tank last week too. Turned the petcocks on and both are leaking :banghead: Tried to save a little bit of cash by not replacing them. But, here we are now haha. I just ordred some from Mikes. Got an email from gordon scott that the mufflers I requested just came in.

Thanks everyone!
 
The bike is looking great!

So, on the throttle again then: did you drill and tap the hole for the bolt then?
 
The bike is looking great!

So, on the throttle again then: did you drill and tap the hole for the bolt then?

Thanks!

Negative. The throttle comes with the holder and nut where the throttle cable inserts, as well as another small bolt and nut behind it. I'm not sure what purpose it serves; maybe a throttle stop for certain bikes?

Anyhow, I used the small bolt and nut to tighten on the retainer that I bought from Mikes. The retainer catches just enough of the cable to keep it from wiggling around :thumbsup:
 
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Sweeeeeeet. Not sure what I did wrong here. Sprayed a bit of simple green to help it slide on. Worked fine all the way till the end and it tore.

The kickstarter rubber I ordered incorrrectly. Ordering the 15mm diameter one now.



A little preview of the pipes that are on the way from Gordon Scott. I wanted the headers to be a bit shorter, but Gordon explained to me the complications and that it wasn't possible. Can't wait to get them dialed in and put on the bike! The headers will be "cerra-coated" (what the powder coat place told me) black, and the muffler will be powder coated black. I'm thinking of leaving the tip of the muffler stainless. Might leave a nice touch to it.

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GUESS WHAT FELLAS!


Used two water bottles with holes drilled in the caps to feed the fuel lines :laugh:
Had a fan running in front of the engine. After it first started for about 15 seconds I killed it, and removed the valve covers. Plenty of oil in the head. Fired it back up.

Starts up first kick every time with the choke on. Not so much with the choke off. Sometimes it will run with the choke off, other times as soon as I turn the choke off it dies.

Not too stressed about that part. Just happy to hear no valves hitting pistons, etc.

I'll start tuning it when I get the petcocks on the tank this week. I don't want to use the water bottle trick again haha.

This is how I decided to set up the breather. Left the rubber plugs inside of the breather nipples. One side is plugged (someone suggest a better/cleaner way to do so please) and the other side has a power brake check valve going to a small filter.

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Looking good!

I got myself the Gordon Scott short cone mufflers, but have my own headers. I haven't put them on yet. Now I'm hoping they are not too short!

Als I've had an idea how to do the breather tubes neatly, but as my enginge is out I can't test it yet. Will let you know (and see) when I do.
 
Well done 51. I have a new to me 1983 xs650 special. been dreaming about putting an RMZ front end on it (raced Suzukis as a kid) and jumping into a build.

My apologies for not adding to the build conversation, but you've inspired me - to leave it alone! After seeing your fantastic work, cool aesthetics, and attention to detail I've come to the conclusion that it would take me a couple of years worth of Sundays to do half the job you did.

So, I'll follow talented builders like yourself and the other extremely talented people on your string, ride my bike stock, squirrel away some parts, and maybe pull the trigger some day!
 
Looking good!

I got myself the Gordon Scott short cone mufflers, but have my own headers. I haven't put them on yet. Now I'm hoping they are not too short!

Als I've had an idea how to do the breather tubes neatly, but as my enginge is out I can't test it yet. Will let you know (and see) when I do.

Sounds good! :thumbsup:
 
Well done 51. I have a new to me 1983 xs650 special. been dreaming about putting an RMZ front end on it (raced Suzukis as a kid) and jumping into a build.

My apologies for not adding to the build conversation, but you've inspired me - to leave it alone! After seeing your fantastic work, cool aesthetics, and attention to detail I've come to the conclusion that it would take me a couple of years worth of Sundays to do half the job you did.

So, I'll follow talented builders like yourself and the other extremely talented people on your string, ride my bike stock, squirrel away some parts, and maybe pull the trigger some day!

Thanks a lot for the kind words JayR! It's a love/hate relationship with these builds. I'm closing in on the final stages and it's very difficult to stay patient. It's been about 7 months now, I'm ready to go out and ride this damn thing!

It would be really cool to see a RMZ front end put on one of these things! If you do pull the trigger I'll follow you on the long journey :bike:
 
I was suprised to see a large package on my front porch today! USPS tracking said these were supposed to show up on friday.

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I'll be dropping these off at the powder coating shop tomorrow.
 
Got some more goodies in the mail; throttle assembly, cable, headlight bracket, left side control switch.

Headlight mounted.

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Left side control switch.

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JBM carb holders (correct ones were sent) Really impressed with these things. Now...how to carb sync without barbs? :shrug: Looking for some hose clamps to use on them.

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Can someone explain what it is I'm missing here? Bought this throttle and cable from TC bros, in the description it said "works well with xs650 and stock cables." Not sure if what their saying is BS or if I'm not catching onto something.

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The cable can pop out easily at anytime.

Head scratcher number #2 Even with the cable adjusted all the way out, still doesnt reach the carbs. (I'll be cleaning that rust off that one part where the cable sits in, just noticed it) Also, the throttle tube doesnt spin easily on the bar. Almost have to use two hands to turn it :eek: I'm going to sand the gloss black off the handlebar and see if that does it.

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That's all for today :bike:

hey man i dont know if you figured it out but i have the same one. heres what i did the bottom screw is some kind of stop/cruise control thing. Remove the screw and the metal tap inside the assembly, then find a shorter screw and use the original locking tab/cable holder twithout thee other adjuster it comes with you dont need it the cable has one built into it for when it strethes. then youll have the perfect cable length
 
just read through looks like youve figured it out haha id just use a shorter screw for the bottom and a washer under the holder so its the same height as the tab of the throttle cable
 
nice build. I have 78 650 special in the middle of rebuild. Do you do your own PC as there is a bit done on your build. I PC'ed my frame, tank, front and rear fenders, air boxes, motor mounts, mag wheels but left the original parts polished, cases and lower crank halves,lower forks,discs were drilled and PC in the center,triple clamps,tach & speedo. Still have to finish assembly of the motor should be ready for some spring rides. Heading to Florida next week with my son for a week for some MX
 
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