650GTS - Nasty Bobber Build

650gts

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I have a 78 that I'm about to start disassembling. I'm going to hardtail it with a Voodoo MK21.
I plan to leave the engine in while I tack weld the hardtail into place.

Is there any particular order that I should follow while taking apart down to the frame?
Just take pics and bag and label everything?

I also plan to start a build thread here to keep track of things.
Thanks.
:thumbsup:
 
No particular order... whatever works best for you and what you have to work with. You can edit the title of this thread and make it your build thread.
Welcome to the forum and yes.... we like pictures here... lots of pics. :D
 
Be sure to remove anything electrical from the frame and the engine. If your using the engine to keep the center tube and all the mounts in line that`s understandable but it`s never a good idea to weld with the engine in the frame. MIG or TIG?? Do you have access to a mock up engine? VooDoo is neat stuff. Good luck with your build.:thumbsup:
 
Still got the jig I made up when I did my "surgery". Cover shipping and it's yours...with one caveat - pass it on to someone else if they need it. We'll just add it to the "Floating Tools" group.
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I just did a TC Bros hardtail (got it cheap) I really like the voodoo stuff. Maybe next? Removed all electrical. Left the motor in while I chopped. I made a spacer to keep the axle space right. 8 1/2" on the hardtail. I tacked everything really well. Hardtail to frame. I only have a mig welder. Then removed the motor. I took the sidecover off the left side. I kept the clutch side on. Didn't want to possibly damage the clutch basket. Took out top motor mounts. Took out the backbone motor mount plates. I Layed the bike down on cardboard with stator side down. Took out the remaining mounting bolts. Wiggled the engine free from the frame. If you can get the exhaust studs out before all this...hell yeah. My stator and rotor were junk too. If yours are not, maybe consider another route, I've done it this way about a dozen times now. Haha. Maybe I should read the manual? That'd be to easy.... Good luck, have fun and look fed to seeing your project! Oh yeah, pipe insulation after its painted during the assembly process. Saves from a few scratches.
 
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Here are some pics of what I'm starting with. I had it shipped to me, so when I got it I started it up to make sure everything worked.
Runs real smooth. The choke lever is missing, so I need to fix that. I still need to take it on the road to shift through the gears before tearing it down.
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I'm about to order a replacement OEM choke lever, but it only comes with the lever. What else do I need?
Just the screw and the washer? The Mike's XS kit looks like it has some other stuff with it.

I have the manuals but can't seem to find a breakdown of this.
Thanks.
 
Update January 2022
Bike is completely apart.
Converting to kick-only with Hugh's CDI system.
Voodoo hardtail welded in.
Stripped frame and treated with a dirty patina and sealed. I like it ugly.

Now it's going back together
Shortened the forks 3" with Hugh's kit
Installed new All Balls tapered steering stem bearings/races.

Progress Pix
A few closeups of the nasty finish - it's so ugly I love it.
Forks are halfway slid in on these pix.
 

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There's just one little thing I can see that's off. If you examine the notched nuts for the steering stem, you'll find they have one flat side and one that's beveled around the I.D. .....

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They should be installed beveled side facing beveled side (your top one has the bevel up). They tighten together more progressively and with more "feel" this way. Install them flat side towards flat side and they lock together almost instantly with no progression or "feel". Presenting the flat side down on the lower nut also applies preload to the bearing better, and the flat side up on the top nut supports the top tree better.
 
Moved onto getting my wheels assembled and mounted.
I went with Avon Speedmasters for front and back. 16rear and 21front.

Cleaned up the rear drum, lubed the cam, and installed new shoes.
Some pix of the rear wheel loosely in place.
 

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