1980 XS650SE (aus- xs650g? special) rehabilitation

festerandolini

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Victoria, Australia
I have a 1980 xs650 special. This wonderful machine came to my attention a few years ago (probably 2013-2015) as it entered the stable of a local casting/sculpture legend. He was looking for some mid-life rejuvenation in the form of re-living his youth smashing through the south island twisties of of the Nouveau Hebridean sister to our nation- that land of the long white cloud ☁️ Aotearoa- or it's English name New Zealand. We often have too long a conversation about motorcycle, machine, metal and more. I am always holding him up from doing more important and probably paid work. So one day after asking him about a falcon he had sitting idle (a 1978 XC 4 door- brown of course, with an auto and the 250 cross flow), he mentioned he would consider selling his XS. He had talen it apart with illusions of spare time, and it awaited his expenditure of time and capital, hidden away in the back shed.

The XS650 Spec. waited for a human soul for a number of years, spread out over pallet and tub, shelf and floor. It was to be betrothed to a son or daughter, but as they are all overseas travelling, working full time on their music career, or studying to be professional something... The XS continuing to sit idle. An offer was made to one of the offspring, but as finances and adventures on the European continent (more probably, just Germany- and specifically the art district in Berlin) held up the interests, time and valuable currency of said motorcycle enthusiast, the youngling passed on the offer for the bike to be traded and money was sent to Germany.

I had to screw things around financial wise. The Chequer Ex-Checker in Chief, none the wiser to my Machiavellian plot, of obtaining yet more rust and junk for the crusty Dragons Hoard.

Cash ported in pocket, off i sped- trailer hitched and ropes stowed. Ready to pick up the long awaited project of many delusional imaginings. Less of the bike appeared to be picked up than i remembered made up a complete motorcycle, from my instincts and from my colander like sconce. Yet, i know that most of what i saw needed a thorough careening, etching, scrubbing and decontamination. Vermin having used the ancient steed in it's dishevelment as some kind of super-gantry to nest and nutrition.

Once my spinal disks had herniated some more, and the Special was loaded up into the trailer and tied off, i departed in a most excited manner. Not quite believing my score, given the recent quote by Geoff's XS for a project machine. I carefully drove to the secret hideaway (my workshop- which is a rented space, suburbs away from the dwelling, where dark arts and secret rituals of alchemy and intoxication are performed) to discharge the freight in a manner that may or may not completely be hobbling. A sack trolley was found and the task of washing the muck off commenced with truck wash and a few scrubbing brushes, rags and a hose.

As fast as i could all of the nest, waste and excetretia of critters was removed revealing a layer of chain lube, engine oil and neglect. More cleaning liberated most of the build up from the last of the 20th century, revealing factory frame coating, patina, use and abuse. Everything, on the frame or near it, the ground and the atmosphere was generously applied the magic forcefield of WD-40. What was unnecessary was wiped off with the remainder of the dry rags and then squared away int the hall of failu... Er, i mean shed.

It has taken months of looking, cleaning, sorting and dry assembling to figure what is needed to get it back on the road again, and as it turns out 'complete' may mean 89%.
 

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A few points of difference on the Oceania models, from US models

Points ignition. B type charging system, (brushes).

Ignition switch has 4 wires coming off it. 4th wire is for the park light. Extra key switch position on R/l, (Red-blue) wire

Park light in the head light

Pass switch on the left bar switch.

Light checker.

Headlight on/of on the right bar switch.

This diagram is for the Euro US Custom models, (Special's). Points ignition

NOTE: B/r wire from light checker runs next to Br wire to, Red warning, brake/Tail light failure light on dash
Looks like a brown wire in the diagram
XS650SE_UK_Model_copyright.Lighst.11.jpg


I used a combination of a US 78SE and 79SF diagrams when i replaced my Oceania 3W6 - 80SG loom with a second hand US 78/79 loom. This was before I got the above diagram.
Use with caution. No guarantees, but pretty sure it will b compatable

P1030208_resixe_copyright_text.jpg


ID thread with links. Post #7 has a small list of links to tutorials that will come in handy for the rebuild and some solutions to troubleshooting electrics

https://www.xs650.com/threads/xs650...-other-information-including-xs750-850.30569/
 
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A few points of difference on the Oceania models, from US models

Points ignition.
Park light in the headlight.
Pass switch on the left bar switch.
Light checker.
Headlight on/of on the right bar switch.

This diagram is for the Euro US Custom models, (Special's). Points ignition

View attachment 356929

I used a combination of a US 78SE and 79SF diagrams when i replaced my Oceania 3W6 - 80SG loom with a second hand US 78/79 loom. This was before I got the above diagram.
Use with caution. No guarantees, but pretty sure it will b compatable

View attachment 356930

ID thread with links. Post #7 has a small list of links to tutorials that will come in handy for the rebuild and some solutions to troubleshooting electrics

https://www.xs650.com/threads/xs650...-other-information-including-xs750-850.30569/
Thank you, i will have a good look. I have lots of documentation, and keep the factory manual on the phone. I have also printed a half size manual (latest one for the later '70s with a bulletin update for 1980)
That is correct, the lights I/o/O switch on the right group switch block and the pass/test on the left. It also has a light saver block under the seat, looks like a later "upgrade". Havent checked the 'magical' sometimes-on non-permanent magnet stator, and points system. I would prefer to keep it, as points create spark gap emissions, and with some smart add-ons, i can use it as a radio transmitter for fun times and pranks. Pranks are fun.

Got a battery, but waiting for the carburettor rebuild kits to do a basic engine run test.

The last 2 weeks have been interesting, i have been throwing money at my problems, on ebay at least. Maybe also ChinaXpress too...

The biggest work apart from taking the cleaning and polishing to another level is the time i ha e been spending in CAD making meshes of existing parts i need for this project and my XS250.

So far i have found some bolt sets for the chassis, loose collections of random parts and some new service parts. I have the XS250 to feed also, and it just got some new brake components (lines, rebuild kits and seals) but the master cylinder on the XS650 was pretty fuc... I mean, non functional. I still need a few chassis components and have a seat cover on the way.

I spend a little bit every pay on the bikes and spend nearly an hour of chaotic time pottering, pondering, and generally just pointlessly fiddling. Cleaning and polishing is all i can do that is productive until i get some bolts, but the constant playing with the bits makes more sense when i do put things together.
 
Here are some more photos, just after i got it all laid up in the shed the first time. I am actually a bit paranoid that i have all the bits, but have actually just misplaced them. This is why i took photos, so i can go back through them and see, what it was or was not that i did not remember.
 

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