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Build Thread...Special to Cafe Bike

Discussion in 'The Garage' started by MaxPete, Jan 13, 2017.

  1. aldo5468

    aldo5468 Redleg XS650.com Supporter

    Well, I've heard of twisting them, as a euphemism for aggravating a lady
  2. aldo5468

    aldo5468 Redleg XS650.com Supporter

    Pete, it gets easier with practice - I eventually replaced the 21" rim in the pic I posted with a 19" one and its associated spoke set. Happy now; never again!
    MaxPete and Jim like this.
  3. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Well, we’ll see. I just ordered about $400 worth of stuff for the three chicks so my wallet is pretty sore right now.

    Thanks for the thought though.
    Jim likes this.
  4. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Ahhhhhh......just got some news. This is gooooodd....
    Jim likes this.
  5. jetmechmarty

    jetmechmarty What should I put here? XS650.com Supporter Top Contributor

    So, how long are you planning to keep us hanging in suspense?

    Mailman, MaxPete, Jim and 1 other person like this.
  6. Jim

    Jim Beyond the edge is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Pete's 750 tank for Demi is up next in the paint room. Rear mount is bent down too far to work on the 650 frame.

    Petes 750 tank 01.jpg

    Petes 750 tank 1.jpg

    A little cuttin' and a tap tap here and there.....

    Petes 750 tank 11.jpg

    Welded back together. Added a little filler metal to beef up the sides....

    Petes 750 tank 21.jpg

    .... and a mockup shot just because. :rolleyes:

    Petes 750 tank 31.jpg
  7. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    LOVE LOVE LOVE those bars Jim - a bit cattywompus, but very stylish!

  8. arcticXS

    arcticXS XS650 Guru Top Contributor

    I am a little bit confused regarding the fuel capacity of the 750 tank. Some websites say it is only 15 liters/ 4 US gallons. Is this correct?
    That seems to be a very small tank for a rather thirsty touring bike, I would have guessed 20 liters, or maybe even more. If that is/was the case, it would be tempting to get one for longer rides.

    And a question for Pete & Jim: Are you modding the tank, so it fits the 650 mounts, and future tank swaps are easy, or are you modding the frame mounts instead?
    Jim likes this.
  9. Mailman

    Mailman Hardly a Guru Top Contributor

    It’s almost like he knows what he’s doin! :D Hey Jim you ought to keep that tank...you have the beginnings af a nice little cafe bike. :whistle:

    So what’s the color scheme on this little beauty?
    GLJ, Raymond, MaxPete and 2 others like this.
  10. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    I think that the XS750 tank is 20 litres Arctic and I have modded the front mounts on the frame. The front mounts on the tank will remain as original and the rear mount has been modified to suit the XS650 frame.

    ....and for Mailman: the colour scheme of the re-born Demi will be revealed....in due course. I think it’s going to be quite striking and I have a couple of very nice touches to add after Jim does his magic.
    GLJ, Team Junk, Raymond and 1 other person like this.
  11. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Lucille and I went for a short ride the other day and on the way home I noted that the neutral light wasn’t working. I figured it was the switch as I had swapped out all of the incandescent bulbs for LEDs which are a direct replacement (thanks for the recommendation Daniel Black).

    Anyhow, the neutral switch looked OK so I took the tach apart (she’s a 1976 C-model) and sure enough, I had left one or two incandescents in there (prolly too cheap to stop using what were perfectly good bulbs) so I finished the switchover to LEDs and she is now back on top-line. Here is a photo of the burnt out incandescent and the replacement LED - along with the package from SuperBrite LEDs.

    They are not expensive and should last forever. If you want a set, they are readily available online and are cheaper by the 10 pack. An XS650 requires either 9 or 10 LEDs for a full replacement of all instrument illumination and warning lights.
    NOTE: I think that later models take a different bulb so be sure to check which type of socket your bike has. Both the ‘76C and the ‘78E have the push & turn type socket.



    ...and here is the finished product (as befits the name, these puppies are bright).


    After getting Lucille sorted out, I put Betty back on the lift to straighten her badly bent headlight ears and remove the voltmeter that was installed on the instrument binnacle. It worked well, but in my view it is a bit too intrusive and with the snazzy new paint job, I’d like to go back to a more “original” look. Sooo, I am now deep into the dreaded headlight bucket :yikes:.


    QUESTION: Does anybody know how to get the trip-odometer reset knob off the speedometer on a ‘78E?

    Last edited: Jun 1, 2020
    Raymond, Mailman, GLJ and 2 others like this.
  12. Machine

    Machine Race the wind Top Contributor

  13. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Well, I can slot the bracket and get it off that way, but I’d rather not if possible - so I’ll hold off for a while to see if someone knows the trick. I have also taken the opportunity to switch all of the instrument bulbs on Betty over to LEDs as this will greatly improve serviceability.

    When I first got Lucille, nearly all of the instrument illumination and indicators and warning lights were burnt out and so I installed all-new incandescents. Within a few weeks of getting her going, I had burnt about 3 or 4 of the new bulbs and it has been a constant battle to keep them all working ever since (I’m a bit OCD about lights). So I was grateful to be able to switch to the LEDs a couple of years ago when Daniel pointed the way to the direct replacements from SuperBrite LEDs.

    Anyhow, once this little voltmeter task is done, I will be just about complete on my list of things to do on both Betty and Lucille and can switch back over to Demi full-blast. I do like having a voltmeter on the XS650s and so I’ll try to find a more discrete location for it.

    Suggestions welcome!

    Jim likes this.
  14. nighthog

    nighthog Lifelong member of the Easily Led Club

    AFAIK, they are all the same. It's just a left-hand thread.
    Jim, arcticXS and MaxPete like this.
  15. Machine

    Machine Race the wind Top Contributor

    Here is a volt meter suggestion I have pondered for myself even.
    I don't really think its necessary to monitor voltage all the time but It would be cool to have both a low voltage warning light , say that unused headlight dash indicator and a volt meter under the seat to view easily at stops ?
    I've wanted that set up awhile and hope to get there some day..
    YamadudeXS650C and MaxPete like this.
  16. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Pete,
    the speedo reset knob threads off.
    Turn it backwards to the way it's turned to reset the trip odometer.
    You hafta grip it's shaft with needle-nose pliers because it's been stuck on there since 1878.
    MaxPete likes this.
  17. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Hi Fred: I tried that but there isn’t any shaft exposed upon which I can grip with pliers.

  18. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi Pete,
    Dremel the access hole bigger so a small needle nose can access the shaft or see if an enlarged hole will let the speedo's innards pull out knob and all?
    Best I can guess without dressing up like an Eskimo to check the dead speedos in my garage.
    Last edited: Mar 22, 2020
  19. MaxPete

    MaxPete Lucille, Betty & Demi - I suggest but THEY decide. XS650.com Supporter Top Contributor

    Naw - I will just make a little slot in the VM mounting plate in an unobtrusive spot and slip it off that way thanks Fred. I don’t want to risk damaging the instrument.

    Robin always told me that he felt it was too....forward and I agreed. He intended to do something a little different - and now it’s my turn to do just that. I guess the point is that I don’t need to watch the voltmeter every second, I just want to glance at it every so often.
  20. 5twins

    5twins XS650 Guru Top Contributor

    If you have the headlight bucket removed, I suggest taking the opportunity to paint it's interior. Use a light color and the wiring will be easier to see. I use Rust-Oleum white primer and just brush it on .....


    On the '77-'79 Standards, you can fit a small voltmeter right into the instrument pod .....


    Details are here .....


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