glaswerks
XS650 Newbie (Still a newbie)
I am starting this thread to document the build of my 77 XS650 cafe racer. Bought this bike about a year ago (my wife passed away shortly after buying it so I had other priorites) and finally getting around to starting on the reconstruction and conversion. Been interested in building a cafe racer since about 1973, finally geting around to doing it .
Here is what I was starting with, a 77 that has seen its better days with about 37K miles, but a clean title.
What I bought .
Check out the tank graphics.
Somewhere along the line, a lowering kit was installed.
Project plan.
The following items have been sourced and bought.
NOS XS750 Tank
Cafe seat ( I will intergrate the taillight into the seat).
Triple Clamp (top)
Clip on's
Headlight bucket and fork ears
New bar controls
Radian swingarm.
etc etc etc ...
Engine will be rebuilt, probably into a 750. New bearings, seals, gaskets and probably a crankshaft rebuild if it is needed. Rephase is not planned but open for discussion. Carbs are still an open issue, not sure if I should use the stock 38mm CV carbs or use a 32 or 34 mm Mikuni kit. Open to comments on this one.
Planning a Pameco ignition one of Hughes Handbuilts alternator kits.
Forks will be modified using one of the available kits on the net.
Shocks will probably be Ikon (the new Koni company) for a more retro look but still provide better rear control.
I designed a new solid state rectifier / regulator unit for the bike as well as a solid state flasher unit. All turn indicators and taillight will be LED based. A custom wiring harness will be built. Want all of the electrics under the seat when done. Battery box area to be open.
Front end will be respoked with an 18" wheel and rear will get a new rim and spokes.
Status so far.
The Front end. Mockup to check tank fit.
Battery Box removed. What a pain in the butt to remove this thing .
Another shot of the front end. Clips on's were sourced off of ebay. I may end up replacing the actual bars, these seem really light. The mounts are very nice.
Still have more grinding to do on the tank mounts before mounting the new rubbers.
Still not sure what to do with the loop, remove, replace or.....
The next step is complete the removal of the old wiring harness (which is a total mess).
Here is what I was starting with, a 77 that has seen its better days with about 37K miles, but a clean title.
What I bought .
Check out the tank graphics.
Somewhere along the line, a lowering kit was installed.
Project plan.
The following items have been sourced and bought.
NOS XS750 Tank
Cafe seat ( I will intergrate the taillight into the seat).
Triple Clamp (top)
Clip on's
Headlight bucket and fork ears
New bar controls
Radian swingarm.
etc etc etc ...
Engine will be rebuilt, probably into a 750. New bearings, seals, gaskets and probably a crankshaft rebuild if it is needed. Rephase is not planned but open for discussion. Carbs are still an open issue, not sure if I should use the stock 38mm CV carbs or use a 32 or 34 mm Mikuni kit. Open to comments on this one.
Planning a Pameco ignition one of Hughes Handbuilts alternator kits.
Forks will be modified using one of the available kits on the net.
Shocks will probably be Ikon (the new Koni company) for a more retro look but still provide better rear control.
I designed a new solid state rectifier / regulator unit for the bike as well as a solid state flasher unit. All turn indicators and taillight will be LED based. A custom wiring harness will be built. Want all of the electrics under the seat when done. Battery box area to be open.
Front end will be respoked with an 18" wheel and rear will get a new rim and spokes.
Status so far.
The Front end. Mockup to check tank fit.
Battery Box removed. What a pain in the butt to remove this thing .
Another shot of the front end. Clips on's were sourced off of ebay. I may end up replacing the actual bars, these seem really light. The mounts are very nice.
Still have more grinding to do on the tank mounts before mounting the new rubbers.
Still not sure what to do with the loop, remove, replace or.....
The next step is complete the removal of the old wiring harness (which is a total mess).