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    Xs650 Suzuki katana smash up

    Fabbed up some new side covers.. Used some perforated sheet metal.. Made some new knobs, used the factory mount tabs on the frame..
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    Frame question

    I do not remember a weld between the flat and the round. I cut the boss off and ground it smooth. I believe it is all one piece. I’d imagine they used a jig or spacer to set the inside width, centered it then welded the gap between the frame tube and the flat plate..
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    Xs650 Suzuki katana smash up

    Finally got the seat finished.. turned out pretty well..
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    Xs650 Suzuki katana smash up

    I’ve got it re assembled and took it for a test ride.. drove it fast enough to make my eyes water.. no idea how fast I was going since my speedometer is no longer operational since swapping in the katana setup.. I just got in some shorty mufflers to replace the roached out trumpet horns.. gonna...
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    Xs650 Suzuki katana smash up

    Finished welding.. frame and swingarm is painted.. final reassembly is underway…
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    Xs650 Suzuki katana smash up

    I’ve added mono shock mounts, cut off unused tabs, lowered the seat rails etc.. I have to finish welding everything… had to get good access to weld everything and not spray the engine with weld berries.. so I decided to pull the engine. Once it’s all welded I will have to paint the frame so it...
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    Xs650 Suzuki katana smash up

    When I originally “swapped” the front triple tree I was young and naive aka 10 years ago… I half assed the swap and only had one nut to tighten against the top tapered bearing on the steering stem.. I recently corrected that. Had to trim both nuts in the lathe and remove about a 1/4 inch from...
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    Xs650 Suzuki katana smash up

    Stock Gauge cluster mounted to the katana triple tree. Picture of bracket was first draft. Final product slightly different. More symmetrical.
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    Xs650 Suzuki katana smash up

    Also put in some work on the brake linkage. The original rod for the master cylinder was inside the frame. The new swingarm wouldn’t allow it. I ended up making a bracket to mount the katana master cylinder to the frame rail. Then I made a pivot bracket and utilized an existing mount on the...
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    Xs650 Suzuki katana smash up

    Making progress on the seat.. made my own metal pan, welded on some rubber bumpers to keep the upholstery free floating not touching the frame.. bumpers will sit on the cross supports I added.. I’m going to bolt the seat down rather than make a latch. Need to weld a couple studs to the bottom...
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    Xs650 Suzuki katana smash up

    Decided to ditch the rear fender, so I had some ugly blinker wires showing. Frenched in the taillight on the frame to hide them..
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    Xs650 Suzuki katana smash up

    I googled the weight of an xs650 vs a katana and they are pretty close in weight. The suspension feels good sitting on it. The katana swingarm did add about 4 inches of stretch so it probably won’t be as nimble in the corners.. shouldn’t matter too much, all we have is straight roads around...
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    Xs650 Suzuki katana smash up

    Been a long time coming.. I bought this bike 10 years ago, rode it a couple times and decided I needed to make some changes. My brother had a katana parts bike that he didn’t want anymore(complete bike cut in half minus the motor) and I decided that it was going to be the donor for the project...
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    Katana fork swap

    I've got the rear half of the frame/swingarm/wheel/brake for the katana as well. That is My next project.
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    Katana fork swap

    Just a heads up. Will have to figure out a new speedo setup for this swap as the speedo runs off the front xs wheel. The katanas had an electronic speed sensor on the rear. I am planning on making a mount for my phone and using an app that is fairly accurate.
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    Katana fork swap

    Headlight mounted with original xs fork/headlight bracket. New forks are larger diameter and had to modify the bracket to slide over the new forks. Can't remember if there was a seam on the mount that I split apart to make it fit the larger forks or if I had to cut it.
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    Katana fork swap

    Katana measured 30 3/4 from top of fork to the center of axle. I still have the original xs fork set, it measured 30 1/2. The katana setup is probably a little longer as the measurement was with it installed and likely somewhat compressed. However I did notice/ feel a slight lowered feeling in...
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    Katana fork swap

    I can try and measure the fork length when I get home.
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    Katana fork swap

    Straight forward as it can be. Propped the bike on some cinder blocks to get the front wheel off the ground, removed the whole assembly and put the new in. Took about 2 hours maybe. The katana and my xs both use the same diameter stem for the triples. Tapered bearings were definitely an upgrade...
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    Which wiring harness do I need

    79 special. So I was told. But I see on the frame sticker that it says mfd. by yamaha motor co ltd 12/77. Vin # 2fo-109813. So with that being said I believe it is actually a 78. What harness do I order off mikesxs?
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