My first build and first XS650

[missile150]

I started this over on Chop Cult, but decided this would be just as good to have here since this site is specific, and the forums are excellent. The build was actually started last summer. Here is goes in a faster thread to catch up with the other site. Please give me any insight, critizism, etc. I can handle it and I am sure it will make my build better.

Well, here is mine. I bought a 1980 XS650 from a friends dad about 2 months ago. It had sat outside for more than 3 years without being started. I brought it home, put some clean fuel in, drained the carbs, put some jumpers on the wires from a good battery, and after a dozen kicks, the bike started. Hell Yeah! So I decided that I was going to make a bobber out of it. The bike will ultimately have a magneto kit and pamco ignition and run without a battery.

Here is what it looked like to start with. Obviously my kids are excited over the new project.

So then I build a stand to put it on for the assembly/disassembly.

Then the teardown began. I am not using most of the parts, but the ones that I am keeping will be stripped and powdercoated. I do powdercoating as a side hobby for me and others, so that will keep some of my cost down.

I didn't like the original neck gussets, and since the tank is going to be an axe or alien tank, I wasn't too worried about how it was going to mount since they mount to the backbone of the frame. I also removed the bar for the stock ignition coil mount, but kept the upper motor mount. I think it looks cleaner with the open frame. I will have to find a new place for the wiring and coil. I am thinking of a fake steel ball in the rear of the hardtail.

 

[missile150]

Then the fun stuff. I cut off the rear of the bike. I bought a hardtail from Lowbrow Customs for this build. I liked that hardtail because of the gussetting and frame weld coverings they come with. It was a little more expensive, but I wanted that one. I don't have any tig welded pictures yet, but I have the ones of how I tacked it in place.

This is where I made sure the frame was square and even.

 

[missile150]

I decided to cut the tabs off the front forks, powdercoat them (including the uppers except where they go through the fork seals), and use gators to hide that area. They were pretty pitted from being outside in the elements for a while, and I couldn't sand them out enough. My only problem is I have to make the opening in the trees slightly larger, from 1.35 inches to 1.4 inches to make up for the powdercoat thickness.

I then took the front wheel apart. I replaced the bearings and am going with black mini-texture powdercoating and stainless steel spokes. I have them mounted (never did that before and it was a pain in the ass) and I need to learn how to true them up.

The last thing I have done was to build a mount for the solo seat. This is where the build stands for now.

 

[missile150]

OK. So I redid the seat mount. I just showed it mocked up with the seat and my hand in the way. I have the towel keeping the powder coating from being scratched by the bracket I made to go on the mount. (I need to start using my regular camera instead of my phone. Sorry for the grainy pictures.)

So I was able to fix my seat mount, and install the bungs for the 3" hairpin springs, or scissor springs as they are called as well. I also scored a set of risers for 1" bars off of a Vulcan for $20. They are aluminim and should coat up nicely. I have to powder coat a panel for someone this weekend, so I will be doing the seat mount I made as well to give an idea of the color I will be putting on the frame. All of the hardware that I am installing and replacing is going to be stainless steel, also. I though about polishing it all, but I think it will look better with the darker colors of the bike and they style I am looking forl.

I am now going to have to focus on making the triple trees a little larger in diameter to fit the forks with the powder coating on them. But for now, I also have a 1982 XS650 that I will be eventually making into a cafe racer style bike. I am going to use the forks off of it to get the stance of my bike right so I don't have to put the finished ones in and out and chance messing up the finish.

I have also thought about my speedometer issue. I think I am going to put in one of those aviation air speed indicators and use the spacer that Hugh fabricates from Hughshandbuilt to replace the gear on the front tire. I think that would be pretty cool, and different.

I also just received my magneto kit from Hugh today, and although i am not ready for it yet, it was too good of a deal to pass up. Thanks for the deal, Hugh, and the fast shipping.

 

[missile150]

Haven't gotton a lot done lately. Man, life can get too busy sometimes. Anyway, I got my powder coat gun repaired and sprayed the front brake caliper so I can finish rebuilding it. It is a candy translucent green, and the tank, rear fender and seat pan will be the same. The frame will be a sort of off white/almond color. They look real good with the textured black.

Man, things have been crazy. Not too much progress. I got the forward controls in the works. Here are a few shots.

I have also got the engine in pieces. I have a broken cam chain guide and a worn guide to replace. Also, I am going to put in new rings while it is apart. I will get some pictures posted as soon as I can.

 

[missile150]

Got some other stuff done. I bought a mini-lathe and made some pegs for my forward controls.

I also prepped for some satin black ceramic coating from NIC Industries.

 

[missile150]

I started to make some fork spacers for my handlebars and am getting rid of the old, crappy rubber bushings.

Well, I got two of the four riser bushings done. Things have been moving here. I have been doing some powder coating jobs for others. Anyway, here are a few pictures of what they look like.

 

[missile150]

I haven't posted since september of last year? Holy crap, does life get in the way or what?

Well progress has been SLOW, what with all the kids sports, honey do lists, chores, etc, etc, etc. I know, I am preaching to the choir. Well, I did get a few things done.

I finished my brake stay, brake pivot, linkages and return spring, as well as reshaped my forward control levers. I hate them, by the way, and now I have to redo them. I also made a chain tensioner and shift lever to attach to the engine. Man, I need to get moving on this thing.

 

[missile150]

I have actually taken everything off the bike, again, so I could cut and grind off some stuff, and make other stuff look better. I am going to be putting in a motor off of an '81 I have and leave it in the bike so I can go ahead and finish assembling the one that is going into this one for good. I just don't want to scratch it up or anything. I will use the second engine for my mockup for now, but it will eventually go into another bike for my wife. My next projects include rebuilding my engine (about 75% done), disassembling and reviving the rear rim and brake hub, building a fake oil tank for the electrical stuff, and making my powdercoating oven bigger to fit my bike frame in it eventually.

 

[missile150]

I ground down that weld bead so it is nice and smooth now. I have about one inch of travel on that brake stay. With the chain tensioner I should be good to go.

I have also got my stuff to rebuild my rear wheal, ordered my 7/8" z-bars and received my stainless hardware to start reassembling my engine after I get the rest of it ceramic coated. I am also going to start on the fake oil tank for the electrical crap. I got a piece of 6" pipe and am gonna weld on two - 6" half spheres to round off the outside. I found them on this site:

http://customironworks.com/

I will cut out a part of the pipe to leave access and drill some speed holes in it for air circulation and for a coolness factor.

More to come.......

 

[missile150]

So I started to fab up my fake oil tank. I got my two 6" half steel balls this week and cut my pipe down. I got it all welded up, and drilled the hole for my ignition. Now I have to fab up the mounting parts to the bike frame. I am going to cut an access panel facing the rear tire and cut a hole towards the front to bring the wires down the backbone and right into the fake tank. I am going to drill a bunch of holes for cooling since everything will be in this thing.

 

[missile150]

OK, new problem:

I have a 1980 xs650 and had to replace the cam chain tensioner and guide. That required me to break the cam chain. I ordered a master link from MikesXS, part number 01-8815, and it didn't fit. They sent me another one, the same one, and it did not fit. They said they did not carry the one anymore for the 1980, only the earlier models and a different part number, and refunded my money. Then I ordered one through my local dealer, checked the numbers twice with what their computer said it should be before I paid, and guess what? It did not fit again. I am getting frustrated because I want to get my stuff back together.

Now what? I measured the ones I bought with a caliper. They are .117 wide. The cam chain insert, from what I measured, is .100 and is obviously smaller than the replacement master links that I keep getting sent to me.

The Yamaha part number I was given is 94662-19001. Mikexs says it should be OEM number 94500-02106-00. What gives? Any ideas? Thanks for your help.

(I also posted this on xs650.com if you have seen it.)

 

[missile150]

I told the yamaha dealer if it was wrong I was returning it. I may give him the other part number and try again before I just order a new chain. I am not out any money yet.

 

[missile150]

That is what I have so far. I am picking up the other cam chain master link tomorrow and am in the process of redoing my fake oil tank to sit upright like a capsule rather than directly under my seat. I will only have to add a part to the key hole and extend it a bit. Then fab up some bungs and mount them to my downtube. and cut an access hole. I got the trees on and the forks in, but haven"t taken any pictures of that yet. When the tank is done, I will be pulling apart the rear wheel, getting it ready, ordering both front and rear tires and my fender. The it is off to the brakes, controls, wiring, etc., etc., etc.

Man, I just want to ride this thing.

 

[missile150]

Well the new link didn't work either, so I just ordered a new cam chain that comes with the link. Problem solved.

 

[missile150]

Well, I finally coated my engine case this morning. Now I have to wait a few days for it to cure before I start putting my stuff back on. You can see the cylinder heads, covers, etc, hanging all over waiting for their new home.

 

[JAGUARGOD]

Great job goin on there.....you have some Mad skills! I want a powdercoater!

 

[missile150]

Great job goin on there.....you have some Mad skills! I want a powdercoater!

Thanks. I am trying to do most of this myself. I also recently scored a short piece of 3 1/2" aluminum bar so I can start to machine my speedo delete. I am going to be running an airplane air speed indicator instead. Probably in knots, too.

 

[Seattle51]

Lookin good! I really like what you did with the rear brake, and having the frame act as the, not sure what you call it, anti-rotation arm. Great idea, I'm going to look into something similar on mine.

 

[missile150]

Lookin good! I really like what you did with the rear brake, and having the frame act as the, not sure what you call it, anti-rotation arm. Great idea, I'm going to look into something similar on mine.

It is called a brake stay, and thanks. A friend who is into custom bikes suggested it. It is similar to one he has on a triumph he built.