Back in the XS650 game: 1981 Cafe/Tracker

scott s

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I stepped away from vintage bikes for a couple of years. Sold them all and only kept my Triumph Street Scrambler. It's been longer than that since I had an XS650.
I was recently contacted by a friend who is moving out of the country and he offered me a screaming deal on his 1981 XS650. I couldn't turn it down. A quick trip to the South Carolina low country (and one blow out on I-95 later), and I have a bike that is probably only a weekend's work away from being back on the road.

He had it set up as a cafe with rear sets and clip on's. Right now, it has stock pegs and Super Bike bars. It feels much better this way and I think it looks cool, too.

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I'm not a fan of those style pods. I'll probably pick up some K&N style, or UNI filters. Maybe a smaller master cylinder (smaller in shape, not bore size). It also came with some small bullet turn signals but, if I add them, it will probably be some REALLY small and LED, so I can hide them well.
 
The bike trolley was part of the deal. Once I flip some of these other parts, I'll have the bike for pennies.

For better or worse, I also got back into the SOHC4 game. Found a super nice, low mileage, first year CB500 for a song, too. I had already started on it when this deal happened.
Honestly, I'll probably end up keeping them both; a restored/preserved/original CB500 and a killer custom XS650.

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The only other thing I may do is look for a slimmer style brake master cylinder. What's the latest on bolt on caliper/rotor upgrades these days?
Maybe a slotted rotor from an 850 and a bracket to adapt a modern caliper?
 
The only other thing I may do is look for a slimmer style brake master cylinder. What's the latest on bolt on caliper/rotor upgrades these days?
Maybe a slotted rotor from an 850 and a bracket to adapt a modern caliper?
Brembo caliper swaps are pretty popular. Pandemonium makes a bracket for the 35mm forks. Which Brembo caliper exactly slips my mind. FWIW, I did a fork swap on my bike, so I have the slimline master cylinder Hugh does/used to sell sitting on my shelf. Let me knows if it’s of interest to you
 
For best "feel" and modulation, you'll want to match the bore size of the MC to the piston diameter(s) in the caliper. Here's what 3M from Vintage Brake has to say about it. I've marked the stock 650 sizes .....

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The stock MC sizes Yamaha chose are a bit too large. Most of us down-size a little bit, for the later caliper and MC, something in the 11mm to 13mm size. I have an 11mm on my '78, a 1/2" on my '83. Both are used Yamaha items from other models I got off eBay.

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Got a cap coming, as well as some UNI filters.
I'm thinking about putting the CB500 on hiatus and getting the XS on the road. I really do think it will be a short project.
 
Pulled the carbs last week to get better access to the line on the fuel T (it was hard as a rock). Glad I did; the T was super loose and would definitely have leaked. While the bowls and jets looked pretty nice, the slides were stuck from varnish.
I ordered the billet fuel crossover, some new gaskets, installed the missing plugs over the slow jets and took the opportunity to pick up some new diaphragms. Mine were OK, but starting to get really stiff around the edges.

Since I am waiting on parts, I checked and adjusted the cam chain and valves. Squirted a little oil in the top end, since it's been sitting for a while.

Other than that, just piddling around. Polished up the side covers and valve covers lightly (this bike has a certain grunginess about it that I like! Especially with the matte paint). Removed a peeling sticker from the tail piece and wiped down the bodywork. Installed the gas cap.

Come on carbs! I'm ready to fire this thing up!
 
Well, here she is.
1981 Cafe/Tracker thing. Been off the road for at least 8 years. Fully rebuilt the carbs, including new diaphragms. In fact, everything rubber in the fuel system is new, from the gas cap to petcocks to fuel lines. The TCI died on the first start up, so a Gonzo CDI replacement was installed. About the only thing left to do is change the oil and clean the filter.
I'm probably gonna repack the muffler, too.... just a little TOO brappy for my tastes.
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You'd better do some fork travel measuring. Normally, you can't raise the tubes that much in the trees or the fender, or fork brace in your case, will hit the lower tree at full fork compression.
 
You'd better do some fork travel measuring. Normally, you can't raise the tubes that much in the trees or the fender, or fork brace in your case, will hit the lower tree at full fork compression.

The P.O. did that and it all clears fine.

One thing that I WILL probably change if I keep it: that front brake line. I don't like the way it's routed but, with the ends that are on there, I can't route it like I want. May have a new one made up eventually.
 
Rotated the bars forward a bit and swapped out the mirrors for a bar end. Been trying to break loose the drain plug(s) for an oil change and losing that battle. It's especially hard with no center stand and one set of hands. I tried using a wheel chock and the damn thing still fell over.
Might have to bite the bullet and have a shop break them loose for me.

Runs really well with the Gonzo CDI, though!

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