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Thanks a lot for the help. I think I did a much better job this time.

I purchased a master cylinder from Hugh's Handbuilt last year and connected the rear brake light by soldering the wires. It worked great for about a year, and then I guess shorted out. I tried to order a replacement part for it but that wasn't possible but Hugh's Handbuilt actually sent me a...

How long did the bike sit? I'm not sure how much experience you have and I don't have much myself so I find when I do things like spark test etc. it's good to do it a couple of times to make sure I haven'e messed it up. To me it sounded like it could be a carburetor problem because the bike...

Still haven't resolved the horn issue but just wanted to check in. Took the bike out for about a 30 mile ride last evening. Perfect summer night and it was a great ride. The bike is running very well.

The horn stopped working, is there something obvious I should be looking for?

Rerouted the clutch and throttle cables and it is a big difference. The clutch lever has never been this easy to operate, and the engine is idling smoothly without revving. For now.... Just went on a great little ride around town. Once again, thank you for the help.

Away from the bike until the weekend but will let you know how it goes. Thanks a lot for the help.

THANK YOU

I haven't. Do you happen to have a shot of where the throttle cable goes through the handle bars / gauges? Thanks for sending this photo, very helpful.

Here is where I am at so far. Engine is still revving but I know it has something to do with the throttle cable, probably how it is routed. Stripped the paint off the tank as it was all chipped and rusting, primed and clear coated for now. Figuring out what to do for some side panels.

Hey Mutt Great bike! I've been working on an 83 XS650 for a couple of years. Be patient and don't rush anything. This forum is full of characters of all kinds but they will get your bike going. There is so much knowledge here just be patient and ask questions, and good luck!

Wow, thanks for sending those images. All of my cables run along the frame beneath the tank. I may order new cable housings for the clutch and throttle as these have been crimped and bent with all of the work I have done on the bike. If that doesn't help than maybe I will go this route. I...

Looks like you were right something is wrong with the way the clutch cable is run. Gave it a twist and went for a 20 mile ride. I think I need to re-route the clutch and throttle cables. Changed the oil and put in some new gas yesterday and the bike ran well. Thanks

Hey everyone, it's been awhile but I am back at it. The bike starts and idols and I was going to take it for a spin to see what needs work but when I put it in gear it stalls. I think it is the side stand relay switch but I don't know how to disconnect or check to see if it is the problem...

I swapped the "rototiller" bars for Daytona bars over the summer. They are not that expensive so I will probable just order new bars. I tried the lower almost straight bars before the daytona bars but they were to low. Thanks

Thanks for responding. Not sure I understand, the handlebars themselves are sealed at the ends they aren't open ended for the mirrors to fit into.

I'm not back to where the bike is yet but can't wait to get back to work on it. One small problem I need to figure out is that after putting on the new master cylinder I realized the mirrors I have wouldn't fit it. So I ordered some bar end mirrors which I wanted to try out anyway. Being the...

I will be away from the bike for a week or two which is frustrating, but glad to have made a bit of progress. It was slow starting this morning, but idled perfectly for 10 mins. I am going to order a new throttle cable, a new vacuum hose, the round rubber pieces that mount the tank to the...

NJ1639 you were definitely right about the throttle cable I lubed it up but also lubed up the spring at the throttle adjustment screw and though not perfect running much better. Thanks

Adjusted the valves again after reading that they should be done after adjusting the cam chain tensioner. When I started the bike it was having the same problems, backfiring and a lot of smoke. After a minute or so it revved to about 4000 rpm then settled to a solid idle without any backfiring...