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New to XS650’s (and Yamaha) Build

Discussion in 'The Garage' started by Hoser59, Oct 9, 2019.

  1. Sir Real Ed

    Sir Real Ed XS650 Enthusiast

    HOSER59,

    I am curious, what grit sand paper did you use to sand your chrome? I have some that isn't bad, but not good enough to save as chrome. Great idea.
     
    gggGary likes this.
  2. Hoser59

    Hoser59 XS650 Enthusiast

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    I used 180 on a rotary to start, then hand sanded all in one direction with 320 and then 400. I found anything higher than that wouldn’t have as nice of a brushed look. I’m doing something similar to the tank so I’ll grab some pics of that as I get it done.
     
    gggGary likes this.
  3. Sir Real Ed

    Sir Real Ed XS650 Enthusiast

    Thanks. I was planning on starting with 400 and wet sanding of course.
     
  4. Hoser59

    Hoser59 XS650 Enthusiast

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    I’ve been working on the tank for the last week and a bit. Came up with a plan of how I wanted it to look, sort of an old school chopper, rat rod look where I’ll keep some of the imperfections and create a patina.
    799E1378-CF9E-48CD-97BF-2590F718F457.jpeg
    started by getting the tank sanded down to a brushed finish and pulling as much of the dents as I could, then I laid down the black paint along the body lines.
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    Taped and primed the sides before body filler and base coat, but I wasn’t happy with how it turned out so I ended up wet sanding and filling it again.
    6F3BB521-6E7B-4BFC-8F9C-9A77337F399F.jpeg DBEE853B-D115-4069-B843-53D57E619020.jpeg
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    Second round of paint went much better and I took a first crack at the vinyl stripe as well.
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    Still have a bit of work to get the vinyl flat around the curves, I have lots left over if I need to try again. Then I’ve got some more prep work to do sanding the black paint to feather it into the bare metal more and then it’ll get a bunch of coats of 2K clear and the emblems. The gas cap is the same black as well. It’s a very different look than what I started off with in my head but I like it, fits with the other bare metal and the scrambler style.
     
  5. Hoser59

    Hoser59 XS650 Enthusiast

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    Cleaned up the greasy engine, it was a big job and it’s not perfect but it looks much better.
    1E373E33-4C9E-4A4E-A960-3180D52D53C6.jpeg 368BF1DD-7A96-406A-951C-2670D308802C.jpeg
    Got the battery box installed
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    I’m ready to get the motor back in the frame after I clean up the hardware and swap the steering neck races. Any tricks I should be aware of other than laying the engine on its left side and placing the frame over?
     
    gggGary, thuban and Jim like this.
  6. 5twins

    5twins XS650 Guru Top Contributor

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    You lay the engine over on it's right side. The frame fits over the left side of the engine easier than the right side because it's narrower .....

    [​IMG]

    I don't know why the factory did it this way, or if it matters at all, but they stuck the long bottom engine bolt in from the right side. All the parts diagrams I've seen and all the stock bikes I've looked at that I know never had their motors pulled are like this. But, obviously you can't do that with the engine laying on it's right side. So, you'll need to stick it in from the left side then once the bike is upright and the rest of the motor mounts are installed, you can change it around. Like I said, I don't know if it matters, but that's the way the factory did it so that's the way I like to do it too.
     
    Paul Sutton, gggGary, RonXS and 2 others like this.
  7. Hoser59

    Hoser59 XS650 Enthusiast

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    Thanks 5twins! Your photos are insanely helpful :thumbsup:
     
  8. RonXS

    RonXS XS650 Addict

    Nice job Hoser! I just got caught up on your build. I especially like your seat latch. Thanks on the tip for VHT roll bar and chassis paint.
     
    Jim and Hoser59 like this.
  9. Hoser59

    Hoser59 XS650 Enthusiast

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    Thanks Ron!

    Instead of the round emblems I decided to go way outside the box and had some vinyl decals made up
    7365C136-D424-4BB8-8B73-2D381C4F0D9C.jpeg
    I think the tank has got a bit of a 60’s BSA scrambler vibe to it now. The blue tape is just to make sure the stripes don’t lift at all while I finish prepping the tank for clearcoat, which should hopefully be sometime this week. Not everyone’s style I’m sure, but I dig it
     
  10. Hoser59

    Hoser59 XS650 Enthusiast

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    Mounted the new tires this evening as well. Hadn’t changed a motorcycle tire since I used to work in my dads bike shop as a teenager. Went smoother than I had expected after 20 odd years
    1FD1F8B8-EEE2-49EF-B481-5B02DAB84AFB.jpeg B7B04B05-321D-4E38-8DC0-1EACEF4F458F.jpeg
     
  11. Hoser59

    Hoser59 XS650 Enthusiast

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    Got five coats of 2K clear on today. Will need a good buff and polish once it’s hardened. It’s far from perfect but that was part of the plan I suppose...I just call screwups ‘patina’
    36F86375-C23C-47A1-9572-DFE74241A7A0.jpeg
     
    Mailman, Brassneck and RonXS like this.
  12. Hoser59

    Hoser59 XS650 Enthusiast

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    Pic with the flash shows the true color a little better
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  13. Hoser59

    Hoser59 XS650 Enthusiast

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    Started assembly - my favourite part of a build
     
    Superjet, GLJ, Mailman and 1 other person like this.
  14. Mailman

    Mailman Hardly a Guru Top Contributor

    You’re so right, this is the really fun part! I really like those tires, what are they?
     
    GLJ and Jim like this.
  15. Hoser59

    Hoser59 XS650 Enthusiast

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    The rear is a Duro HF904 and the front is a Bridgestone TW39. Bridgestone makes a TW41 with matching tread that fits the rear but every place I tried was out of stock. The Duro has a very similar tread pattern so it’ll work
     
    Paul Sutton, Mailman and Jim like this.
  16. Hoser59

    Hoser59 XS650 Enthusiast

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    Now that I’m seeing It partially together it’s really calling for a black seat. So I’ll have to do that
     
    Superjet, RonXS, GLJ and 2 others like this.
  17. Mailman

    Mailman Hardly a Guru Top Contributor

    This is gonna be a great looking bike!
     
    Superjet, Hoser59 and Jim like this.
  18. Hoser59

    Hoser59 XS650 Enthusiast

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    Started working on the wiring, opened up the new harness as I’m moving most of the components around.
    7FF55469-F7ED-43D7-87F1-761A6C9E848D.png 12C68CC3-FC62-4B2E-8EA3-45901290E0EC.png
     
    Superjet and Mailman like this.
  19. RonXS

    RonXS XS650 Addict

    Your XS is coming together nicely!
     
    Hoser59 likes this.
  20. Superjet

    Superjet XS650 Guru Top Contributor

    I love the look of those tires you got there. Gonna be a great looking bike after all done. :thumbsup:
     
    Hoser59 likes this.

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