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1980 XS650 Brat/ Bobber/ Chopper/ Who Knows? Build

Discussion in 'The Garage' started by B_Crabaugh, Jan 4, 2019.

  1. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    Got the motor all torqued down today. Going to polish up the tappet covers next. Still need to clean the bottom end and give it a bit of fresh paint.

    Question: Is it necessary to use gaskets on the tappet covers if I’m already using o-rings?

    Jim likes this.
  2. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    The gasketed valve covers were used on the early models. Later valve covers include a groove that accepts the o-ring, discontinuing the use of the gasket...
    GLJ and Jim like this.
  3. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    That’s what I thought! Good news! Thanks for the info
    TwoManyXS1Bs, gggGary and Jim like this.
  4. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    Decided to move to the frame today. Had a break in the rain, so why not?! Got to cutting, grinding, and hitting some areas with a polycarbide disc on the grinder. Those things are GREAT!

    Seat area cut

    Mock-up of what shall be

    And one with the tank I’ll be using

    Miiiight be lowering the rear seat section. I’ll know for sure once the swingarm is extended 2” and the wheels are on!
  5. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    Took the frame and swingarm over to @kungfutoast house to get the welding going. Picked up some new steel and we got cuttin’.

    Keeping the stock lower shock mounts as is for now. Might need to move them forward a tad after the mock-up.

    Cut the tubing for the frame and got it in place.

    Welding it in after making sure everything was perfectly level.

    All done on the seat section! Very happy with it!

    Probably going to extend the rear seat an inch or two. We’ll see after the mock-up with wheels and suspension on. Had to put the swingarm on hold due to the wall thickness of the new tubing being too large to accept the solid plugs that we are using. Once that’s sorted, it shall be done!
  6. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    Pulled she starter seal today and installed the dorman freeze plug. Used a 32mm socket, a wooden dowel and a BFH to get it out.

    Cleaned up the area a bit and added a thin smear of rtv before installing the plug

    Used the dowel and hammer to git the plug in. Worked great!

    Btw, what the heck is this bolt/ passage for? Cannot find it in the manual or parts diagrams.

    And with it removed...
  7. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    It's where the shift drum detent and spring reside. Looks like you're missing the spring?

    TwoManyXS1Bs likes this.
  8. B_Crabaugh

    B_Crabaugh XS650 Enthusiast

    Aha! Thank you! I think I have the spring somewhere amongst my pile o’ stuff. Does part 16 in the diagram come out with the spring or is that seated in there?
    Jim likes this.
  9. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    From you pics.... looks like it's still in there.
    TwoManyXS1Bs and B_Crabaugh like this.

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