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'78 Special Brat / Cafe Racer Build

Discussion in 'The Garage' started by SAFU, Sep 14, 2015.

  1. SAFU

    SAFU XS650 Enthusiast

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    Picked up a running '78 special from craigslist with PMA installed kickstart only. Took the battery box out and waiting for Counter Balance brat seat to arrive in a couple days, then plan on cutting the fender and make an electronics pan to hide all the wires.
     

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    Last edited: Sep 17, 2015
  2. SAFU

    SAFU XS650 Enthusiast

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    seat came in today unnamed-7.jpg
     
  3. SAFU

    SAFU XS650 Enthusiast

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    Made an cut an aluminum electronics pan under the seat to hide all the wires. unnamed-9.jpg unnamed-8.jpg
     
  4. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi SAFU and welcome,
    interesting build.
    You gonna run teensy battery or capacitor?
    Most folks who re-wire swap the glass tube fuse block for an automotive style mini-fuse block.
    See scallywag303's fuseblock in the list's classified for as small a unit as you can get.
    You'll need his 3-way + a single to house the stock wiring's 4 fuses.
    And if it's got cooling fins on it, don't put it inside a box, eh?
     
    SAFU likes this.
  5. SAFU

    SAFU XS650 Enthusiast

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    Thanks for the info about the fuse box Fred ill look into that. I mounted a Sparx capacitor to the bolts on the cam chain tensioner case. unnamed-10.jpg
     
  6. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi SAFU,
    OK, the Sparx capacitor is fer sure not sealed away mounted there but what if the carb drips gas on it and some of the sparx get out?
     
    SAFU likes this.
  7. SAFU

    SAFU XS650 Enthusiast

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    Been ghost and just lurking this is my build so far
     

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    jetmechmarty likes this.
  8. lakeview

    lakeview XS650 Guru XS650.com Supporter Top Contributor

    Lots of good details to look at on your bike and I like a lot of them, especially that limited production front wheel. It must have been hard to find. I think some members have had trouble fitting them as well, I was looking for the thread but cannot find it.
    Thanks for the update.
     
    SAFU likes this.
  9. SAFU

    SAFU XS650 Enthusiast

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    yeahhh that makes sense, ill remount it when i get the chance
     
  10. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Nah, if the fender was mounted under the fork brace perhaps it'd rub on the tire.
    And unlike you, I am never wrong.
    But if it were mine I'd stack a few more rubber washers between the fender and the fork brace's rear arch to keep the tire/fender gap the same all round.
     
  11. SAFU

    SAFU XS650 Enthusiast

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    I had no problem installing my wheels, I stumbled upon it on an ebay auction about a year ago for under a 100 bones, I think I was the only bidder but I knew they were rare, seems that there was a XS500 version as well.
     
  12. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi solo,
    there is no "right way".
    There's ways that work well, ways that could work better and there's ways that don't work at all.
    Judging only by SAFU's photo, he's taken the middle ground.
    FWIW, my "throw some washers in there" fix is the quickest and easiest way to move the front fender's heel further from the front tire.
    But to do it properly yes, the fender should mount underneath the forkbrace.
    Where it don't look like it'll fit unless the fork to brace adapters get re-worked to tilt the brace so it's parallel with the fork rather than
    being tilted back the way the photo shows.
     
  13. SAFU

    SAFU XS650 Enthusiast

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    Thanks Fred, always coming through with the knowledge
     
  14. SAFU

    SAFU XS650 Enthusiast

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    Back again from lurking and getting my bike running from sitting, some of the steel have been rusting nicely. Removed the front fender for now as it looks cleaner. Most of the heavier parts has been removed and or replaced, such as the battery, starter, fenders, original seats, stock triple tree. The bike has been rewired and wiring simplified. PMA with sparx capacitor kickstart only, starts in a couple kicks, anymore than that than I know the carbs need to be cleaned. Next on mod on the bike would be to replace the original Pamco electronic ignition with the new Pamco electronic ignition with integrated advancer.
     

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    jetmechmarty and gggGary like this.
  15. krob

    krob XS650 Enthusiast

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    Whats the rear wheel?
     
  16. SAFU

    SAFU XS650 Enthusiast

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    Hey Krob, it's a stock mag rear wheel with two 16" pizza pans bolted together, there is a thread on here that shows you how to.
     
    jetmechmarty, Ozboy and Lou like this.
  17. CoconutPete

    CoconutPete 1979 XS650 Special

    Cool build. Very interesting and different from most of the stuff you see.
     
    SAFU and gggGary like this.
  18. SAFU

    SAFU XS650 Enthusiast

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    Thanks Coconut Pete! :bike::smoke::smoke:
     
  19. SAFU

    SAFU XS650 Enthusiast

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    Simplified wiring harness, was able to hide the capacitor and fuse block under the tank. Mounted a toolbox/registration holder to one of the engine mounts. Relocated the speedometer with a L bracket from hardware store.
     

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  20. rick1956

    rick1956 Just a regular guy.

    I love your choice on the acorn nut colors!
     
    SAFU likes this.

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