1980 XS650 Build

[JET Improvements]

This is the beginning stages of my 1980 XS650 build. It has been slow going to this point as I kept changing my mind from cafe to tracker to brat... I have finally decided, this week anyway, to go more of the cafe route. The first pics are as I brought it home. Then several "in-process" pics. So far I have rebuilt both calipers, changed all fluids, rebuild carbs, replaced swing arm and rear wheel bearings, and started shaving the frame. I will be putting in mad work this week and weekend trying to get it primed, reassembled, and running so I can enjoy it sooner than later. I will tear it apart and do the frame, paint, and engine work real proper over the winter. You can also follow the build on my website at www.jetimprovements.com

Enjoy.

 

[JET Improvements]

More pics.

 

[JET Improvements]

Still more.

 

[hooktool]

Welcome. Keep posting pics. If you have/create/solve any interesting issues, post them up.

John

 

[JET Improvements]

Will do John. Have some more pics to add, but having trouble with the site right now. Unfortunately since posting my plans for the holiday weekend, the dishwasher broke, my son had decided that any solid food is offensive, and my wife announced that one of her college roommates and her two children will be visiting. Suddenly the hours are slipping away. I have several parts on order and as soon as I can get the tank kreem'd, I will work on making it run. Will probably have some questions then. Cheers.

 

[JET Improvements]

So my build is going slower than would I like between two jobs and a family, and my rideable deadline of June 9th is approaching way too fast. Turns out that the rear caliper piston and the rear master were too far gone for a simple rebuild, so those parts are on the way. Went ahead and got a new brake line while I was at it. Since it is about to be my birthday I splurged a bit and also ordered new grips, new 2.5" gauges, and a new combo led tail light. This is were the questions begin. So I did a quick mock up last night and when I hit the turn signal switch all four signals come on and stay on (no flashing). I think that the relay might be shot, but not sure as this is my first dive into older bikes. The previous owner had "deleted" the turn signals and had running lights in the metzer fairing that was on the bike when I bought it. I have been through the schematic several times and my rewire seems sound, yet no flashing. WTH?

Background: I was an ASE certified master tech before an injury ended that a decade or so back. I have owned several bikes in the past but all were new or newer so only had regular maintenance on those. This is my first bike resurrection. Any and all help is appreciated.

Cheers!
James

 

[JET Improvements]

Also started mocking up my seat pan, but the wife announced today that she is thinking about changing her mind and may want to ride with me. Looks like it is time to change the seat design. I will post updated build pics this evening.

 

[XSLeo]

Build two seats. On solo, one two up.
Leo

 

[hooktool]

A wife that likes to ride with you doesn't mind you buying stuff and working on the bike quite so much. My wife is almost always on the back unless I'm just running an errand.

John

 

[JET Improvements]

This is as far as I got before my birthday deadline. Been riding it since June but snapped my clutch cable the week before leaving for leaving town. Parts arrived but haven't had time to replace it yet. I had much bigger plans for this project, but riding sooner than later became the priority. I figure I will have plenty of time this winter to tear it all down and take it up a notch or two. She has been nicknamed by a not MC-related client as my bottom bitch, it has kinda stuck.

 

[JET Improvements]

More pics. Yes that is a terry cloth towel as a seat cover. It was 0230 when I went in the house for more caffeine when I saw it, the dog towel. The bleach out job on it just seemed to match the ratty look that developed. It has already been a sogginess on a couple rainy days!