My "build thread" one year late.

Kel-Lo

XS650 Member
Messages
10
Reaction score
31
Points
13
Location
Mpls
Hey all, I joined this forum a little over a year ago and a bit overzealously talked about starting a "build thread".
Well things happened and I was unable to really get started on this project until recently.
I'm not in any hurry, I primarily only work on this project on the weekends and not sure how much will get done during riding season so it might be a two or three winter project! (It's my first real build project).
Appreciate this site and the wealth of knowledge, extremely helpful.
Here are some pics of the engine after top end work, paint and polish. Probably not going to run these pipes much past initial startup, seems the general consensus is the stock header pipes are to small. Thinking I'll buy a full exhaust at some point. Wanted to try something with the stock headers anyway. I left the full length internal header and welded in an outer filler piece and the cheapie shorty mufflers. I know there are flaws, it's not perfect, but some of you have set the bar to freaking high! LOL.
20210116_190919.jpg
20210116_191226.jpg
20210116_191519 - Copy.jpg
20210116_193237.jpg
 
Hi Kel-Lo,
I’m happy to see you started a build thread, it looks like you’re off to a great start! The engine looks very sanitary. I like the look of your header pipes, they almost look like black chrome, what type of finish is that?
 
what type of finish is that?
Thanks. I sandblasted, then sanded with 800 grit, primed painted and clear coated with rustoleum 2000 degree high heat spray paint. I used the same finish on my Street Glide pipes about 20k miles ago and they have held up well. That being said, I actually planned on wrapping these and still might.
Here's my sweet "paint booth" LOL.
20210117_100024.jpg 20210113_052227.jpg
 
Thanks. I sandblasted, then sanded with 800 grit, primed painted and clear coated with rustoleum 2000 degree high heat spray paint. I used the same finish on my Street Glide pipes about 20k miles ago and they have held up well. That being said, I actually planned on wrapping these and still might.
Here's my sweet "paint booth" LOL.
View attachment 182881 View attachment 182882

Wow, I never would’ve dreamed that paint would hold up to that heat.
 
On the contrary, I think you've done a fine job there. It looks great. I really like your engine stand too. Looks like a bench top style with a removable rolling base?

One thing I will mention - I don't see the tin shrouds or covers on the intake manifolds. You're going to need/want those or the manifolds won't hold up for long, especially since the carbs are no longer supported by the airboxes because you're running pods .....

ZC8Ganx.jpg


Also, kick start rubbers are still available from Yamaha and not too expensive, but be aware that there were two different ones used. Early bikes up to about 1980 had a 15mm diameter shaft for the rubber to fit on. Later bikes used a smaller 13mm diameter shaft. Yours is most likely the earlier, bigger diameter shaft but check it to be sure. The 15mm .....

https://www.partzilla.com/product/y...?ref=4ac71d31534f64808762b5e7fb4bba52915afcf3

..... and the 13mm .....

https://www.partzilla.com/product/y...?ref=50fff24e18e95e555c9eff3013a50b84f78e6768
 
5twins, thanks for the input! I do have the intake shrouds. Not going to lie I was hoping to be able to run without them, but if you say that's a bad idea I believe you.
It's pretty much just mocked up right now, still need to go through/ re build the carbs. Since I have you here, what would you suggest for a starting point for carb jetting with the set up I have??
 
I'm not in any hurry, I primarily only work on this project on the weekends and not sure how much will get done during riding season so it might be a two or three winter project! (It's my first real build project).
Lookin So fine! Take all the time you like.
:thumbsup:
Have you seen a "single outlet crankcase breather" from an 80 up engine?
20200821_183034.jpg
-R
 
If those are '78-'79 carbs, you may need two up on the mains (from 135 stock to 140). You will also need to lean the needles a step. With the large stock 135 mains (largest put in any 650 carb set), the upper midrange is borderline too rich right from the factory. Any increase in main jet size will push it over the edge and cause break-up in the upper midrange under heavy throttle applications. And yes, one up on the pilots too. Sometimes two up also works well (from 27.5 stock to 32.5). Years ago you couldn't do this because Mikuni didn't make the 32.5 size. They jumped 5 numbers from 30 to 35, and a 35 is usually too much.
 
Your jetting will depend largely on the exhaust system in the end. I try to run bikes on the lean side, combined with precise ignition settings.
(Points ignition)
:thumbsup:
 
Since the motor is still out and easy to access, do a few head bolt torque checks. The gaskets will compress some after a few days sitting and you may find some loose bolts. Also do another check after you've run it a few times and put it through a couple heat cycles. The expansion and contraction associated with the heat cycles will really bed the gaskets in.
 
Thanks for the advice and information. I'm a long ways from startup but will keep it all in mind.
I have to take a couple of weeks to get caught up on some other things around the house, then I should be able to get started on the frame. Not chopping anything, just stripping it down, media blasting and painting. Plan on doing a fairly simple cafe style build.
I will post any additional questions and progress in this thread.
 
Don't worry about taking a while, my bike took 2 years to "finished" and is still somewhat ongoing with changes.
 
Back
Top