Paramun - build thread

[Ristis]

Hello everybody!

I have been reading forum from some time, decided to start a new thread and this is my first post here. Let me introduce myself - my name is Hristo, 35, I am from Bulgaria - Eastern Europe. Don't have much experience with bikes - two years ago I restored an old Simson AWO Touren 250cc from 1956, which is pretty simple bike compared to XS.

Here in BG there is no XS650 bikes for sale, so I was forced to search it abroad and bought my XS650 SE '79 3L1 from Germany via e-bay. Previous owner was a german gay who used to travel around Europe and spent 66 000 km with it. Before 11 years he gave up with motorcycles and left the bike in his garage...

My goal is to make a street tracker looking bike, to remove unnecessary weight, and to assemble it as reliable as possible for short weekend ridings. "Paramun" is a name of a mountain.

Please excuse my English ...ask my teacher, I will try to post more pictures.

Any comments or questions would be highly appreciated!

What I had:

And some fragments of what I have done up to now:

- frame:

- Stainless engine mount:

- exhaust pipes modification:

- carbon fenders:

- carbon seat pad:

- carbon electric box:

 

[xskid]

Amesome, loving that carbon fiber work. Keep it coming man

Posted via Mobile

 

[oldbiker]

Hello everybody!

I have been reading forum from some time, decided to start a new thread and this is my first post here. Let me introduce myself - my name is Hristo, 35, I am from Bulgaria - Eastern Europe. Don't have much experience with bikes - two years ago I restored an old Simson AWO Touren 250cc from 1956, which is pretty simple bike compared to XS.

Here in BG there is no XS650 bikes for sale, so I was forced to search it abroad and bought my XS650 SE '79 3L1 from Germany via e-bay. Previous owner was a german gay who used to travel around Europe and spent 66 000 km with it. Before 11 years he gave up with motorcycles and left the bike in his garage...

My goal is to make a street tracker looking bike, to remove unnecessary weight, and to assemble it as reliable as possible for short weekend ridings. "Paramun" is a name of a mountain.

Please excuse my English ...ask my teacher, I will try to post more pictures.

Any comments or questions would be highly appreciated!

What I had:

And some fragments of what I have done up to now:

- frame:

- Stainless engine mount:

- exhaust pipes modification:

- carbon fenders:

- carbon seat pad:

- carbon electric box:

.......................... hi i absolutely luv the stainless steel motor mount its fantastic regards oldbiker

 

[ippytattoo]

I agree with the previous posts and would like to add that your English is just fine. Keep up the good work and keep the pics coming.

 

[Ristis]

Thank you for the feedback!

@ oldbiker - engine mount has pretty simple design. I was inspired from link from here, a gay who produce and sells them. Then I tough how I can make it more easy and without special tolls to assemble. It took me few hours to turn round parts on lathe, and plates were laser cut. All parts were fixed with pressing and whole construction is self adjusting, only the two washers are silver soldered.

Fenders are vacuum moulded, didn't measure rear, but front one weights 300grm/0.660lbs

Now the whole bike is disassembled into pieces (except engine).
Paint was cleaned with soda and I split parts into three groups:
- metal ones - frame, swingarm, tank, fork holder, side stand... are given for hot zinc cover
- aluminium - rims, fork boots, steering, brakes are for black eloxation
- small metal parts, nuts, footrests, kick/brake/gear levers, etc... - are given for new chrome

 

[Ristis]

Just got the metal parts from hot zinc cover:

Tank is very well sealed - inside and outside. Hope my fuel filter will be clean for a very long time. This tank is not the original one, but I find it much better looking:

Unfortunately at close distance things are not so good. A lot of zinc drops stuck at the parts ends unable to fall off.

At the frame things are even worse, especially on the right side. M10 threads are literally full and some M6 nuts are tapped with zinc.

Now I have to find a way to smooth the surfaces again before powder coat...

 

[80brat]

That motor mount is cool nice work

 

[Ristis]

This hot zinc is horrible and I made a mistake with it. All threads were full with zinc and decided to clear all parts except fuel tank. Luckily zinc can be quickly removed with HCl acid:

Drops of zinc (black cover) at the yoke bearing place:

After 45 min:

 

[I am Carbon]

Welcome to the site
Your build is coming along fine.
On the regulator/rectifier, I would make sure to have good air flow across it.
They can get hot

 

[Ristis]

Hey, Carbon, thank you for reading the thread and the advice, I will keep that in mind!
I made thin teflon shims to ensure distance between rectifier and electric box. The rectifier seems to me too big (didn't expected) and took a lot of space from the box.

Again - ZINC This time electrochemical and the results are much better. In fact there is nothing in common with hot zinc. The layer is very thin, threads and bearings holes are intact:

And I took the aluminum parts from eloxation/anodization. As they are cast made, the color became MAT even on polished parts as boots:

I wonder about color scheme of the bike - rims, brakes are black mat, all bolts, nuts, pegs, levers, etc. are with shiny new chrome...?

 

[Ristis]

Assembled front shock absorbers:

And rear brake pump with new repair kit:

Wheels are ready too, working on speedo drive eliminator...

 

[Paulrxs650]

Hi Ristis, I like the build and the different uses of zinc coating. What style of build are you going for - Tracker, Cafe Racer?

 

[Ristis]

Hi Paulrxs650, your bobber and cafe builds are very interesting and stylish! I'm not going for Cafe Racer even I found some of them awesome. My wish is to build more comfortable to ride bike with straight body position. Our roads here are not so good and this is my main consideration to put clip-ons away.
Zinc is one of the best metal covers/preparations before powder coating. If I didn't choose powder coat I have to airbrush with epoxy based paint. Electrochemical zinc is not so good for tanks and all closed spaces. Inside they remain uncovered because of the shadow...

Here some pictures of wheels, equipped with new bearings, seals and chromed parts. Probably I will put back the old tyres as long as this build won't be finished soon:

And my sketch of speedo delete:

 

[Paulrxs650]

Thanks Ristis. Nice technical drawing, what is that programme you are using?

 

[Byookanun]

Very cool build. Subscribing.

 

[Ristis]

Some pictures of my progress...

New stainless steel brake pistons:

Brakes with new rebuild kits:

Someone may need this (in mm...):

Do not liked "Pyramid" bearings - very rough finish at rings inside...

Drilled and zink plated brake disks. Drilling took much more time than I expected:

El. box with stainless steel plates and rubber mounts:

Bluesea systems fuse box fited - it's bigger then normal but build quality is very good:

Mockup - with new Hagon shock absorbers. At swingarm, pivot tube was scratched and bronze bushing were damaged. I couldn't find good/new pivot tube so I polished an old one (-0.1mm) and made cylindrical bushings from technical plastic. There is no need for this plastic to be greased and to prevent it from dust, at the ends, I used two seals HONDA 91254-KS7-831 DUST SEAL (22X28X5) - which fits perfectly at swingarm holes:

 

[bornleader]

Great build and attention to detail!

Like the B&W photos as well.

 

[Fings369]

Any New progress? Would love to know your plans for the seat, Thinking about doing some fiberglass/carbon fiber for a seat myself

 

[cafeguy]

Awesome build! keep up the good work

 

[wannabridin]

updates!!