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The handlebar switch is a new repop unit, nothing pinched. Bars are aftermarket... everything is powdercoated. The carbs are rubbed mounted via JBM boots. The starter button works so it's grounding through the bars as intended. I'll try adding a ground wire. I'd be interested if others bikes...

So my long term '79 Special project is 98% complete. I've been casing small issues like the starter staying engaged for a second or two after it starts up.... Anyways while I was messing with it I figured I'd check the cam chain tension. The engine is a fresh 700 with a bunch of good parts...

Assembling in the living room 2 years ago now with the OG engine.

cleaned up the frame, removed the center stand, muffler mounts, passenger pegs, reflector mounts etc... Back from powder coat....

No a good friend of mine has done the majority of it.. I had a local place to the frame..(post to come)

These are the carbs off the '83... painted them black again, all new stainless hardware. 2 up on the main, 1 on the pilot. I've never liked to look of the narrow special tank with the offset filler... so I found a solid standard tank and had it done right...

I ended up drilling a larger front rotor... at the time I didn't realized there was a difference. Didn't help I got like bike in 100 pieces.

Battery and fuse box....

Bobbed the front fender which I didn't up using... still trying to figure out a good looking solution for this... Exhaust was next, this took FOREVER! At this point in time I had gotten the front end back from powder coat as well as the brake calipers and mounting brackets...

The first thing I had powdercoated was the wheels.. Then I drilled the rotors. I had a buddy draw a pattern up in illustrator then print it out on clear vinyl. Stuck it to the rotor so I could center punch all the holes. Shaved the upper triple clamp and fork leg... Milton mod for the...

Now that this project is wrapping up I figured I could start a build thread. I have ton's of photos so this may take a while to tell the story..... This all started over 4 years ago when I picked up 2 XS650's. One a complete 1983 Heritage Special, the other a hardtail 1979 Special. I gave the...

Thanks guys... this project has certainly taken long enough, I have ton's of photos from this 4+ year build. Perhaps I'll make a build thread...

No masking........ I sanded them all flat with a 2'' roloc before I had them powder coated. (Stock they are a pretty irregular surface) Once off-gassed and sprayed with powder he wiped off as much powder as he could, then baked and cured them. When I got them back I went over all the surfaces...

I soaked mine for an hour or so, then hung them on a screw and let them drip off any excess

Engine before install. 700 JE pistons, shell #1, KW springs, ported head, 5th gear OD. Barnett springs, Alto 8 friction plate mod, Pamco, PMA.... powder coated everything...etc

No I built it myself with Hoos cones.... had a buddy Cerakote it.

engine installed!

heading to Madison anytime soon? I just picked up some Barnett springs and should probably do this as well.

I was told you are supposed to heat it up, considering I bent them about 1mm I not that worried about it. We do, the head on this engine actually came from you. Chuck grabbed it for me this fall.

Correct just spinning it by hand to check the advance. The stock 14 is too much, I just bent the tabs and reduced it to 10 degrees.