STANDARD issue…. a resurrection begins….

Jim, you reference "From Tech"
The "reference" is actually a "link." It links to the thread...Which years had ball bearning and which years had needle bearings in the head tube?
Or more correctly, comment #15 in that thread. The permalinks here don't always land on the correct comment number so I usually reference the number when I post one. Click on my link above and you'll see what I mean.
 
Time to kill today so I started mounting / mocking a few parts up. Mounted battery box, inner fender, and rear fender. Threw a few parts on the frame to keep me inspired.
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Also put some attention to my air filters. The old foam was totally roached. One of the filter assemblies also came apart so needed glued back down. I tried some Gorilla glue and seems to be holding well.
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That deteriorated foam just disinterested when you look at it. I spent a little time cleaning it up before cutting new UNI foam to fit. I just need to glue the seams together. I can use the same glue, but that seem will turn rock hard. Anyone have suggestions for glueing the ends together? Overall I’m pretty happy with the results.
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I also bought some early headlight ears on eBay today to mount the headlight. I just like the looks of the early mounts a lot better. I know they are shorter than the 35mm mounts, but I have a plan. I’ve got all the parts from this 77 and parts from my old 78 special. I also think I can use my old fork seals, as well as the incorrect new ones that I received to make spacers to make up the extra half inch. I’ve got a vision. It should work out ok me thinks :umm:
 
The "reference" is actually a "link." It links to the thread...Which years had ball bearning and which years had needle bearings in the head tube?
Or more correctly, comment #15 in that thread. The permalinks here don't always land on the correct comment number so I usually reference the number when I post one. Click on my link above and you'll see what I mean.
I had been to the "Tech" section. "TECHNICAL REFERENCES" and say thanks to all who contributed there. I just did not correlate #14 until I spent more time perusing because "Body and Frame" (?) could be construed as 68-96 because so many contributors have offered so many threads of wisdom on so many subjects. I am lucky to have a cool old beast and an information source like this XS650.com site.
 
For what it’s worth , I’ll tell you how I did this. I cut the foam about a half inch wider than the filter cage so it fits in nice and snug against the edges, I also cut it long enough for the ends to overlap. Then instead of gluing it, I’ve got this green vinyl coated twist wire , that I picked up in the garden shop at the local home center, it comes on a roll, it’s cheap and used for tying plants up. Anyways, nobody sees this filter, I wrapped some of that wire around the foam in two places, just to hold it in place. Then when I want to clean it, it’s easy to undo the wires and just take the foam off to wash and re oil. Sorry no photos of the twist wire.

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A bit off topic but perhaps allowable what Foam brand and type is suitable
Sold where ?
I have saved a couple old filter cages .With mostly filters that has bursted open have a hole in them.
Not so dirty.
Also there is a rubber gasket glued on the inside closest to the intake that comes partly off allowing air be sucked in
not passing the filter at all
Anyone replaced the rubber and managed to glue it on. What glue
Any air condition filter materials that has been tested.
3M glue looks expensive.

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For what it’s worth , I’ll tell you how I did this. I cut the foam about a half inch wider than the filter cage so it fits in nice and snug against the edges, I also cut it long enough for the ends to overlap. Then instead of gluing it, I’ve got this green vinyl coated twist wire , that I picked up in the garden shop at the local home center, it comes on a roll, it’s cheap and used for tying plants up. Anyways, nobody sees this filter, I wrapped some of that wire around the foam in two places, just to hold it in place. Then when I want to clean it, it’s easy to undo the wires and just take the foam off to wash and re oil. Sorry no photos of the twist wire.

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Simple solutions are always the best!
 
I've done like mailman and held them in with a couple wraps of safety wire.
Like the finest foam for street use, also like green cuz it's easier to tell when it needs cleaning but the thinner black is prolly enough/easier to work with.
https://unifilter.com/online-catalog/accessories/

Sheets of Air Filter Foam for you to fabricate your own design! There are five types from coarse to fine to choose from.

UNI AIR FILTER – FOAM SHEETS
BF-1 – 12″ X 16″ X 5/8″ – 65 PPI Grn fine foam
BF-2 – 12” X 24” X 3/8″ – 30 PPI Blk coarse foam
BF-3 – 8″ X 10″ X 2″ – 30 PPI Blk coarse/Skid
BF-4 – 12 “X 16″ X 3/8″ – 60 PPI Blk fine foam
BF-5 – 12″ X 16″ X 3/8″ – 40 PPI Red coarse foam
BF-6 – 12″ X 16″ X 5/8” – 40/60 PPI Dual Layer

A bit crude but a filter cut template for the 80 up BS34 plastic air boxes
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Fork seals in and we have a mocked up roller.
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I really need to procure some new shocks! I’ve been eye balling some old Koni 7610’s on eBay. It’s either that or a set of new Hagon’s. I’m leaning towards the Koni’s though.

These wheels are the old one’s off my 75. They are in very good shape with good bearings. All they need is some new tires and sprocket. The parts list continues to grow….
 
I'm a big fan of old Koni shocks and use them on almost all my bikes. For the 650s, I like the 7610-1429. This was originally fitted to Moto Guzzis in the late '70s through mid '80s. It has an eye to eye length of 337mm (just over 13 1/4") and is the perfect length, slightly longer than stock. They also have offset bottom eyes and this works nicely on the 650 .....

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Quick little update, got my early fork ears in the mail today. Played around with mounting. These early ears are about 5/8” shorter than the later ones off my 77. I used two sets of fork seals and the old rubber bushing off the 77 ears and worked out pretty well. I can grab some more detailed pics later for the orientation, but pretty happy with it. I’m not 100% on the gaitors though.
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Are those the Daystar truck shock boots? If so, you need to shorten them up to make them look "right". But, how does one go about that and still retain their nice fitting tops AND bottoms? Here's how - start by cutting off the nice fitting top along with the first bellow still attached to it .....

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Now you'll do the actual shortening. Cut the next 4 or 5 bellows off, whatever it takes to get the gaiter length just right. Then, since these boots taper from small bellows at the top to larger ones down lower, simply insert that top collar and one bellow inside the top bellow on your shortened gaiter. It's a perfect, friction fit .....

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Before I fitted a fork brace, I had mine shortened to 8 bellows. Once I added the fork brace, I had to remove one more so now have 7 .....

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Chipping away, one part at a time. So much corrosion and grease and grime. I find myself cleaning most stuff up on a wire wheel chucked in the drill press. I started by cleaning up the front fender. It’s got a few dings and some pitted rusty chrome, but shined up pretty decent. I have to keep reminding myself this is just a resurrection and not restoration.
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Also put the correct rear fender back on. Along with the correct tins. I also dug out my nice ‘75 seat to play dress up. Finished mounting the headlight and also trimmed down the gaitors per 5T’s suggestion above. Everything is very loosely mocked up right now. I continue to test fit different parts as I’m still not 100% exactly what direction this will end up going. Very doubtful I put the indicators back on, but am on the fence if I use the gauges and cluster.
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