Hyde's Build

Hyde

XS650 Addict
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Location
Brampton, ON, CA
Alright, I admittedly have been half avoiding a post on my build and progress but it's time. 82 XS was picked up last October - tacked on hardtail & 5 boxes of parts. PO started a chop but never moved on it and I got a hell of a deal.

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I've owned a few bikes and pretty comfortable with motor rebuilds - tech section here was pure gold throughout it all. Rings, cross hatch, valves, valve tappets, timing chain, guides, clutch, pushrod, all seals and gaskets. The only thing I strayed from was cracking the block which did get a fresh coat of paint. And of course what good are fresh guts if she's still covered in 30+ years of grime - vapor blast to the top end.

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I'm no stranger to buffing, paid rent in university doing transport trucks and cars for a shop on the side. This made the casing easy work to get cleaned up. And as always the devil's in the details. I've gone so far as to pull all visible case bolts for polishing as well.

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So here's the jewel sparking on the bench in an after/before. To those who have helped along the way, ty much - you guys have been awesome

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When it comes to mechanical = all cool, but i know my capabilities vs. build quality wishes. So some jobs like welding/fabrication - I'm happy to source out to the moto community I ride with in the summer. Enter the frame. PO did tack her straight. Essentially, I sketch it / demo where something is/need to be in my head & my buddy Rob makes it.

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Loved the rear fender supports on one of the Chappell bros builds along with the mount point to the fender. Yes, you can crack a TC Bros catalogue open and reference along on the bike. Note the 6in fender. It needed some good splicing to match tire curvature. Gonna be a blast to cleanup for paint lol.

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Next is the infamous (per other thread) fancy pants Munit . On a cafe they are "easier" to hide, but this thing is wide open. Oil tank welded up closed, door and hinge placed on the front. The idea here is that I can easily access it for config & run my electrical from can, into frame and then either forwards or back. Tank is a direct ground so long as I keep all contact point free of powder coat.

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Bike originally had mags, I wanted spokes...shiny and in great shape. This began a hunt for a 16 in hub off a wreck 7 ON wreckers later I found one lol. NOS rim off of eBay - was rather in shock at how amazing its condition was. Hub took about 4 hours to get polished up. Never laced a rim in my life, but after a couple of YouTube hours, she's done and like brand new.

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And of course, what's a hardtail without a proper springer up front. -2 Harley (stock XS) from TC, 21 inch front rim. Not easy to get ahold of, they've been out of stock since the end of Oct. It took a few phone calls to work something out After that experience, I can say those guy's are fantastic!

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At this point I'm waiting on the last of the frame cleanup before powedercoat. Bailing wire has been run front to back terminating at the can. Paint will be starting up shortly by yours truly.
 
That's some great work there. I'll be watching...
 
Long time since updating the post. Got all my parts back from powder and chrome recently and began the re-assembly stage. This is the part I enjoy the most as it's the least stressful compared to what I've also been friggin with.

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Dropping the frame over the engine to mount it is soooo convenient.

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Keep in mind, this is a weekends project bike so time is limited and was heavily consumed the past couple of months with bodywork and paint.... fender was contoured to fit the back tire. Tank is pretty hardcore raw and needed ALOT of attention to smoothen out and a black base would show every flaw I missed. Well, after converting a spare bedroom to a paint booth for a week, I'm through to the first heavy clear layer and paint work complete!

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This is the second true paint job I've done and would be homeless if it was my full time job lol. Altogether I've got about 26 hours into the fender and 30 into the tank. But....they came out fantastic, no flaws in the metal/bondo surfaces came back to haunt me. They've been setting up a week and will get some wetsand love shortly followed by another heavy clear bath so I can burry the lines.
 
On the side tinkering (waiting on my clearcoat) made some excellent progress as well with CDI/PMA/MUnit installation and the first crack at hearing her run. It was killing me to of never heard her start and boy did i grin when I got her going


Flack for the PMA fully accepted, it's Hugh's system with the new Regulator. We'll have to see how she goes.

Question though, she's popping at idle after getting warmed up. There's no exhaust seals in right now (still have to wrap pipes) and no filters on the carbs. Timing looks good, triple checked valves Sunday, just looking for early advice - my lack of seals potentially root cause of pops? Oldskool (Rick) rebuilt the 34's in December for pods and I had mentioned open pipes so they are pristine. Whole lot of reassembly/wiring to do before I get to tuning stages.
 
Hey folks, 90% through the build now. Gremlins left to be tracked down and exorcised. Core issue with enricher on the BS34's remains but we'll get there.

So for the electrical part of this bike - HHB PMA/CDI & the Motogadget Munit - meshed seamlessly, zero issues. All electrical (outputs) forward into headlight bucket (where applicable) then bullets out to power front end. Here's a shot of the oil can with final wiring inside. The "loaded" side is all the outputs, skinny side inputs for signaling to the unit.

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As for input, mbutton input from mini buttons on the bars, Yellow rear brake switch and brown the other side of my ignition lock.

Mini buttons on bars wired to the Mbutton (buried inside bars) according to function. Left/Right, Horn, Headlight (on/off/hibeam all in 1 button) Start (click twice and it's a kill switch). Total of 2 wires into bars (power for blaze bar signals) & 3 out (ground, green to Munit, control button for Speedo) FYR - blaze signals are intensely bright, 2 LEDs forward and 1 LED backfacing. It's not often anyone picks up that I even have signals installed till lit.

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1 extra button wired to control the Chronoclassic speedometer digital display. Kinda neat (didn't realize) that I ended up with battery voltage as well. 12.2 is the current state after cranking on the starter yesterday day chasing gremlins .

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So ignition switch, well I'm this far buried with Motogadget, why not just keep rolling German? RFID with a fob. Made a special mount and powder coated to hide up just behind the neck where the left and right sides of the frame merge, very well hidden.

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As to the fob, I keep it in my wallet "just in case". The pill in the pic below has been sewn into the tip of my glove. Reach under and she flips on - same for off. Fancy pants? Of course, but it's hella fun no? Heh.

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I'm running almost the same setup as you, electronics wise. Keep up the great work!! I'm wiring this week, any helpful pointers?
 
Heh I can give you a few after this experience.

Motogadget is gonna throw a lot of bulky "recommendations" on wire gauge - take close note of how overkill those gauges are when it comes to your build components and only run what's already dangling off them.

Hugh's PMA/CDI - leave your Halogen bulb in place, do not swap it and also keep the standard bulbs in the back end. You want to bleed as much juice off naturally as possible.

When it comes to grounding Hugh's MOSFET, it grounds out to whatever it's mounted to, there's no ground wire. Makes sure there's a super clean/prepped surface to attach & as a backup measure, make and extra wire to run off the mount bolt which grounds in/on the frame. I'm still heavily weary of the regulator based on the prior version reported problems.

Air....do not hide the MOSFET, make sure it can breath off heat uninhibited. I've got a powdered/steel plate that mounts in behind the front engine mount. Reg in the front for air, CDI mounted directly behind it. Well hidden and blends with the build.

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Look at that MT-01, those are such great looking bikes. I don't think they ever started selling those in the US(I haven't really been paying attention though, so I could be wrong), so I've been jealous every time I see someone in Canada that has one.

Bike is looking great so far! Always nice to find an abandoned project so you don't have to feel bad chopping up a good frame. Seeing you guys clean these bikes and engines like this really makes me jealous of the time you have to work on your bikes. I plan on spending way more time in the garage once my kids get older and don't require as much attention.
 
Well I was in a dead panic to get this ride finished and ready for a self-powered ride to the Freedom Machines show in Durham ON (July 22nd). I'm proud to say she (and I) made it there and back in 1 piece without any major issues.

The bike had only been around the block 3 times chasing carb issues - zero road time. Compound that with a "temp" sticker (no Ontario safety yet) and it was one hell of a nerve racking ride. Gates opened at 11am, I didn't finish my final review till 12pm..but damnit I made it and she was super well received. Few pics for ya to see the near final product.

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In the process now of post-show/safety preparation so 1/4 of it is apart again lol. Need to fab a "front fender", chain guard, mount actual mufflers and move my plate/tail light to the sissy. This can all be taken in stride. Thank you to everyone here to provided advice throughout my build. Really appreciate everyone's input and the wealth of knowledge here that pulled it off!
 
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