An introduction and question

Having more options is always a good thing. I'm guessing the relay that has separate units on a single plate are for later models? May I ask what years to look for?

BTW, what screen shot programs are ya all using? When employed we used Snagit, but it was free to us or maybe it was a free download at the time. I would rather put $49.95 into parts rather than screen shot software.
 
'77 was the last year for the single, starter only relay. '78 and newer had the double starter and headlight relay. I suppose either would work for you. You'd be cutting it down, just using the starter relay portion.

For screen shots, I just hit the "Print Screen" button on my keyboard then paste the saved image into the "Paint" program. From there, I can crop and edit it to the portion and size I want. As far as pics go, I crop and resize them with a free photo editing program (Fly Free Photo Editing) then upload them to a photo hosting site (I'm using Imgur at the moment). Hosting them on an internet site makes sticking them in posts very easy. This is all free.
 
I use Snipping Tool. It came free with Windows.
 
This is a chrome extension, Full Page Screenshot, works great with both, full page, and snippet screen captures..
 
I'm in need of a bit of advice on using an XS1 head and cover on a later model engine. The XS1 head has a cross over tube on the intakes and I was wondering if it is something I should keep or block off when using it on a later model engine. Also, I was planning on using BS34's on it but do have a set of BS38's from the mid 70's I can use too. Any recommendations on which set would be best.
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While parts engine parts are out getting machined for valve seats and cylinder boring I spent the afternoon making a stud puller. yeah, I enjoy making chips. :)
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Real straight forward process. Hunk of metal. stainless in this case. Face off, drill a pilot hole through, bore to .875" for collet shank then cut angle that forces collet tight on stud. The funnest part was knurling and cutting hex head.

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Tomorrow I make some collets and post some pics.
 
Little update from Ozark. Finished the stud puller. I forgot to add a pin that keeps the collet from rotating during tightening so I had to back track a bit.
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I need to get by a hobby store and pick up a piece of RC plane control rod to make a keeper that will hold the bolt in the collet holder. That'll be a rainy day project.

I also bit the bullet and ordered fork tubes from Franks. They are top quality but getting the dampeners (I'm guessing that is what one would call them) off the old tubes and onto the new ones was proving to be a bit of a pain. Solution... I made some new dampeners.
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The original dampeners are what I would call a pretty loose slip fit on the end of the fork tube and I just was not seeing a good way to re-pin them due to the loose fit. Mine are an interference fit, about .002" on the ID below the internal groove with the upper ID a nice slip fit to the tube. I did a slip fit on the top because the wall at the groove is pretty

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And to ensure they stay put they got pinned too.

Now for electric start on the orange bike.
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Is the resistor bridging the two relays needed?
 
Nice work Jake!!
You won't need the resistor unless using the light relay also? If you just want the starter relay, wire it like this... you won't need either the diode or the resistor.

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Thanks gggGary and go for it. I really like to see what folks are doing machine wise. My formal machinist days ended years ago, but I've kept it as a hobby. Probably why I still enjoy it so much, cuz it has been a hobby and not a living.

Thanks Jim, that really helps. I was looking at factory wiring diagrams and the diode thing was making me real nervous. I also started to cut down a double unit this afternoon making it smaller for out of the way mounting. When I get mounting figured out I'll post a pic. I'm trying to figure out how to test it when it's all wired up and in place without having the bike running that is. About 2 months back I tried to start it and still limping around. Any suggestions????
 
Little update from Ozark. Finished the stud puller.

Confess I am once again blown away by the types of fabrication and level of work you guys undertake at home. Of course, there are garden shed machinists in Britain, but I would guess they are thin on the ground here. In N America it seems to be almost normal for people to have machine tools, lathes, pillar drills, polishing machines and welding equipment in the garage. And the knowledge to go with that. Or maybe you guys are not typical?

Respect.
 
I follow Butchered Classics on facebook, Mostly UK custom bike builders. There is a lot of quality work going on there also.
A home workshop with at least a tool box, basic auto, and woodworking tools is pretty typical of USA homeowners. More extensive shops are prolly more common in rural areas where an acre or more means a fair amount of equipment needing care just to maintain the property.
Doing what Jake is showing here has my respect! That level of skill is unusual everywhere.
 
I follow Butchered Classics on facebook, Mostly UK custom bike builders. There is a lot of quality work going on there also.

Jake - sorry for the digression. Gary, just took a look at Butchered Classics and I like the style of bikes Dave Solomon is turning out.

If I were 20 years younger . . .
 
It's been while since I've posted any updates: waiting on parts, got side tracked on a non-650 hobby in the shop, etc... I got a call from a buddy that is getting my frame powder coated and it will be done next Tuesday, so I thought I should try and get some 650 stuff done which means getting the electric start figured out so I can get the orange bike off the stand. So this is a call out to the electric types for some help. Quick catch up on where I was and going. I got the safety relay and starter solenoid ready to mount but wanted to do a bench test wire up to test the safety relay but needed a 6 AC volt source. Low and behold my son has a variac from a biology lab that goes to 6 volts. My question is how do I wire it to the safety relay? The out put wiring of the variac is the standard two wire with ground.
 
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