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1972 Resto/Retro Project

Discussion in 'The Garage' started by jones5944, Dec 31, 2015.

  1. jones5944

    jones5944 XS650 Enthusiast

    My goal is to build a 1972 XS2 which is a replica of the bike I owned, built and rode in the early to mid-70's. This is my starting point. Let the fun begin!

    Original - right side.jpg
  2. Welcome along. I'll watch with interest :) Pop some more pics up as you get along.
  3. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    mm 72! Watch the front axle, brake assembly some tricky one year only stuff, parts there.
  4. Nice,never seen a blue one before.
  5. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Ditto !!!
  6. vr3506

    vr3506 vr3506

    Nice project!

    Was this blue an original Yamaha colour on this bike?
    I also heard about a blue XS1
  7. jones5944

    jones5944 XS650 Enthusiast

    Thank you for your comments. I look forward to sharing this experience and I hope that everybody has a safe and prosperous New Year.
    The blue paint was over the original red paint.

    I disassembled the bike and all the parts were cataloged and bagged to match the Yamaha parts catalog. For me it makes easier parts location during re-assembly.

    All chrome work to be re-plated was inspected and pictures sent to several plating companies for quotes. I determined that the rims were to far gone to be re-plated and will purchase new

    The parts to be painted were chemically stripped, inspected and prepped for paint.

    Luckily the gas tank only had minor rust and was easily cleaned with a chemical rust dissolver and some light media blasting.
    Brackets and components ready for prime.jpg 0714130704a (2).jpg

    Engine brackets ready for prime and paint.jpg 0710131919.jpg

    Frame ready for paint.jpg Items for plating 1.jpg

    Parts stripped and ready for paint.jpg
  8. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Definitely following this. A serious restoration project.
    Also curious about current chrome pricing. Local chrome shop?
    May want to closely examine the rear fender loop. Notorious for developing cracks...
  9. Good to see your restoring the bike. Going to be a fun project. Progress is going great you have a lot done,
  10. jones5944

    jones5944 XS650 Enthusiast

    With regards to the chrome: I have decided to make this bike my daily rider so I probably will elect to go with standard plating instead of a higher quality show plating. Locally we have one shop that you either love their work or hate their work. They have a group they cater to with high quality finishes but if you are not on their A list it might take you along time to get back poor quality re-plates. I sent my request for a quote to shops in Minnesota, Georgia and Kentucky. I will be glad to share their pricing when I get it back. I am also looking at NOS parts. Sometimes I have been surprised to find that a new part can be purchased cheaper.

    I etch primed and then primed all the parts in prep for base and clear coat. I am using PPG products. Luckily very minor fill work was required on the body parts.

    Parts etch primed and primed.jpg

    Frame primed and ready for base coat.jpg


  11. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    Wow nice work going on here. The OP hasn't answered but I'm guessing the blue was a repaint. In the first pic there might be a bit of red peeking out under one headlight ear. The bottom edge stripe on the tank looks a bit thick compared to the stock pin stripe.
  12. jones5944

    jones5944 XS650 Enthusiast


    In yesterdays post I noted that the blue was an overpaint. Sorry you missed it.
  13. gggGary

    gggGary I'm listening, change my mind XS650.com Supporter Top Contributor

    I did miss that, sorry!

    Is the rear hoop fender hole enlarged torn?

    Check the rear hoop especially the RH front for cracking, might want to proactively reinforce weld there. What about the rubber block between hoop and fender? I need to do something about those on several bikes yet. Yes the chrome work is a head scratcher. Yamaha chrome is not as smooth shiny as the good shop$ make it.
  14. jones5944

    jones5944 XS650 Enthusiast

    The rear fender loop hole is enlarged a little and I plan on brazing it closed and reinforcing it at the same time prior to plating. The fender loop is in great condition. I have found the rubber block on fleabay and other sites. You might check out Clauss Studios & Manufacturing in CA. They do a lot of reproduction rubber products plus if they don't have it they might be interested in making one for you.
  15. vr3506

    vr3506 vr3506

    Thanks for the adress ;-)
  16. jones5944

    jones5944 XS650 Enthusiast

    I painted all frame and body components. Will allow the tank, side covers, headlight stays and headlight bucket time to gas off prior to color sand and clearcoat.
    Frame clear coated.jpg

    Painted brackets and frame components.jpg


  17. jones5944

    jones5944 XS650 Enthusiast

    Rear Wheel:
    Disassembled, cleaned and inspected.
    Polished rear brake parts.
    New bearings and seals.
    New polished stainless steel spokes.
    New polished aluminum rims.
    New brake pads.
    New sprocket (32T) and lock tabs.
    True and balance.
    Dunlop K70.

    Front Wheel will undergo the same treatment.

    Stock rear wheel - brake side.jpg
    Original rear wheel
    Completed rear wheel.jpg
    Restored rear wheel
  18. SkavenDC

    SkavenDC Just Some Guy With a Bike

    Following this as well. Can't wait to see how this turns out.
  19. jones5944

    jones5944 XS650 Enthusiast

    Ready for assembly.jpg

    Began chassis re-assembly:

    Cleaned all overspray from mounting points and threads.
    Cleaned and inspected all nuts and bolts.
    New tapered bearings in steering head.
    New bronze bushings in swing arm.
    New grease zerks in swing arm bolt. Opened up holes for better grease flow.

    Speedo prior to resto.jpg

    Guages - Ready for re-assembly.jpg

    While waiting for front end parts I am dismantling the speedo and tach and will clean and install new face graphics.
  20. vr3506

    vr3506 vr3506

    Where did you get those speedo and tacho graphics from?

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