BC XS650 bobber/chopper build

New Years update… with a few more update pics…

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The neverending to-do list:
  • Electrical
  • Hydraulic clutch
  • Rebuild brake calipers
  • Hydraulic hoses
  • Plumb gas tank
  • Rebuild carbs
  • Tuning
 
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Ooooohhh - pretty! I'll bet those springs are just-a-bouncin' with that hardtail!

Very nice clean job indeed!

Pete
 
Great job!! Love the "classic" look you went with. It reminds me of the BSA my father in laws reenacting buddy has from WW2.

Glad to see I'm not the only one cutting up a pair of fork covers to make them work. I'm going to be "borrowing" some of your pictures to reference as I cut mine up.
 
So an update, electrical and rebuilding of the brake calipers have been taken care of… so now on to the hydraulic clutch…

I had seen a few posts of members taking existing OEM slave cylinders and modifying them, or the cover that they mount to, and in some cases the pushrod in order to make it all work… I wanted something that would not require any modifications to the cover... a true bolt on...

Along the way I stumbled on to mrriggs write up of a stealth homemade purpose built clutch:
http://www.thechopperunderground.com/forum/index.php?showtopic=72802
http://xs650temp.proboards.com/thread/17567/bolt-on-hydraulic-clutch-conversion

So with his stealth clutch as the inspiration I decided to try my own version of the slave cylinder. With the cover essentially blocking access to the mounting area it is difficult to get an idea of what will actually fit in that area. Luckily there have been others who had created CAD solid models with decent detail in the cover and push rod area:
https://grabcad.com/library/yamaha-xs650-engine-1

Using this and my familiarity with AutoDesk Inventor, I was able to CAD up a version that used the existing M5 mounting holes:



Here are a few cross sectional views:

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CFCcrrWet-keZgiC-NSeDdw1jW7H9Tifd-G7u7LVgD9aBJHpdIDnYMp7JnUEZY_eSr91U3j8lYt50IDTbdv8GAPwVaxVpdcYgL8G_fy6mwI1Y6-WUWCDEhl0UvVR5gq4Jdz1NSv9AFKJnMrAkaJ5aRcqFNxvbqHF7-G_frAw0RN4XOslcbk3IPJ-XBp5hoGqcB0VmBrCzR1nWjzLaDvNxGP2sOcNU0Qk9nro_GovLMfhsPVI2kA9BnaSpsbVF2KTSUZfpZcSC0K7RgmMw7aq_cl1DctyFcNCHhBsfZCA-i3bEZSwJLkiXubpUMrkTm7-RcHxIX5ADkot5dE29TZ4CGRQcC6A4544xCihA_4GMhYNeTQGi5r_emRju8dhshA4ER7V2DN0VrSvZpHQusJZ1vF0IaxHr4WypAx20PHkdai7xECf59_2enLfUfZh_dELQuRgeudvGAkI7xIjTqetjgUAJ6LjXOat9hucvkQuNqfXn0_xS7k9bkSfTKUqj9QOrzHhwaHWZQ_cLl24J4_h6ujq9UoVhQ5hBxZlbLdOzG72Qt7c_-8gxitdg4on7S0t9Ax4gMyh00SCvQ0iJNPR0IZzi8PwatC06oZ86AQF1F6Kik2TZnob=w1093-h780-no


I decided on a design that in addition to the traditional housing and piston, contained a third adapter piece. The rationale behind the third piece is that it would be easier to tweak it on final fitment, as opposed to disassembling the actuator.

I deviated from the true stealth approach of mrriggs as I decided on using an axial M10 fluid port going through the worm gear chrome access cover. I also managed to fit a 28mm piston, which I thought was a good match for the 12.9mm master cylinder that I will be using.

One of the benefits of 3D modeling is that you can “print” the model in a variety of plastics to visualize and test fit your concept. Later on in the process you can export the output of the 3D model and import into a CAD/CAM software package as a starting basis for CNC machining.

Below are two versions that I printed out.
Prototype #1, version with axial M10 port:

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Cover, front side with hydraulic fitting (still needing a bleeder banjo bolt)

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Prototype #2, version with radial M10 port (not used):

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As mentioned above, I decided on the axial M10 port because of ease of machining, and my preference to not route the hydraulic cable through the “busy” frame.

Last week, I had the parts machined, and hopefully this week I will machine the adapter piece for final fitment.

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:cheers:
 
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Well done Oddjob ! well done indeed !
I just found your thread here and I like Bobbers and will continue to follow this in the future !
I am with Fredintoon about the ride of the hard tail so don't forget about letting us know the difference between the two Please !
I am watching this with interest as I would like to turn My '83 XS650 heritage into a bobber , I really like their look its a "Chopper done right" to me!
but I was thinking of keeping the rear suspension and all on mine but that raises the seat height up a long way...i dunno ...I'll probably never do it
but I'ed like to ! perhaps when the Ranch sells I can afford such things ! HAHAHAH!
you've done yourself proud boy ! AND this was a very good thread THANK YOU for shareing!
...
Bob........
 
So I finally rounded up all the bits required to hook up the slave cylinder... with a 28mm piston and 12.9mm master cylinder I managed about 2.4-2.6mm of stroke...

Extended piston shown below... the piston normally sits flush with the housing...

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So up next, another first... rebuilding the carbs...

:cheers:
 
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So on to carburetor rebuilding/cleaning...

Its that time of the year where people are cleaning out their carbs so I though I would add to the carb porn... :D

Crappy before pic...

kqvvLzX-vFVNGZGM-GE3CUX6g3L4tfbH4s58bne1MGUJSPSuNk01Lq9508VrxcTBzbs8oc4YsrIQt1pp3knKbD7oI_xWYem2ah14xANgYhMWCWSA21Fby8QEMfjcPeyGuoq7tkkxDyt72uXftEhLliuCtSwVmDAoZhoifjasIHvK5DehYPcWdn8B-3DdiY0GozyuPVEAouuw9RtTPtEwKP-8VJRphAx2R-Qb1RIg5TIOTWk5LTh4ZmEgU2STzINhb5TcJWOpbHKlEEGlgxfTAd4SefQAxKMsMqltYLXekdjbzoDAT76hDSn4CJmwTRwe0XV-VUTcSGHnF86NwiF2Zy6u0mRlR19OyX5p44t74Owq403FTKnfFc7_J-S3x9lsm_3Pifw4yNsMFQCUSv7E4wOh93T1wGz1RisICROlV9Z7ErLJC35pz1i2j6V6fSiwS9G5GLrTPrviOD-GBp_eWUSZR9XsrgL-nRyBEHqNnYxT4yx8ZKzbeWi8TGiGmw3LwlCjbAhfkYL0RDSriW3zBcs7Vstw1rLNOeZ1DfMCdB-NGYuzR_OIMlJpMNgEk1JbMgQbw85g5BIQRetG_siCj1YS9OkWPZ-sKj1FnXxaLTAnF108VaEv=w1387-h780-no


But of course no carburetor rebuild is complete without taking on a side zinc electroplating project to pretty up all the little bits...

I used the "recipe" in this thread, and was really pleased with the results... much better then having to wait overnight for paint to dry...

http://www.xs650.com/threads/zinc-electroplating.26506/

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To clean the carburetor bodies I used Simple Green Pro HD, 3:1 water ratio and 2-3 hours of ultrasonic cleaning... I was happy with the results and would recommend this over the traditional carb cleaning solvents that I've used in past projects.
After pic... :smoke:

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So I guess one more update… I think I’m finally done…

A few lessons learned…
  • Emgo slash cut mufflers are loud, and make the bike sound angry, Lol… of course not having any real sound dampening material on the baffles doesn’t help. I found that fiberglass rope that is used for stove door gaskets to have very good sound dampening properties.

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  • You will most likely have to rebuild your forks if your bike has been sitting around for a while. I also found as part of this experience, that leaking fork oil and the caliper dust boot as supplied by MikesXS caliper rebuild kit don’t mix very well, thankfully I still had the old one kicking around.
  • On carb jetting/tuning I ended up going two up on the pilots and two up on the mains… Do follow the correct order for tuning (cam chain, valves, points, timing and lastly carburetor) or you might be chasing your tail a bit… do use an inductive timing light, do use a dwell meter… do take apart and lubricate the advance mechanism… do reduce the end play on the advance mechanism...
  • These bike are a tad noisy, valve and cam chain wise…
  • These bikes vibrate a lot, check and recheck multiple times to see if anything has come loose… use Loctite… your garage slab/foundation will sometimes seem to vibrate in unison with the bike… you are not going crazy...
  • Hardtails can provide exciting throttle feedback when going over bumps… Lol…
  • Chain tensioners can still allow the chain to flutter a bit especially when coasting... Lol
  • It is a better idea to size the front brake line length at full suspension droop… Lol
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:cheers:

Cheers
 
Last edited:
thx for the heads up... I blame google... they should be able to predict my errant ways and compensate before I even post...
 
Yeah RG it rains alot in bby... Just not this summer... Lol

As far as the fender... I'm really a fair weather rider, its tricky enough getting around here in nice weather as it is... :D the forks also came partially shaved as part of the basket case... I'm just glad the PO didn't shave off the caliper mounts...
 
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