81 XS650SP. First bike. First build.

user12651

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Hi Everyone!

This is my first motorcycle and my first build. But I think I can do it. My father-in-law, Joe, is helping me out. Before he had his first daughter, my wife, he was a motorcycle mechanic. He's been super supportive and excited to help show me everything. Unfortunately, I'm in Minneapolis and he's in Wisconsin. So the build will take place in his shop and I'll make frequent trips to work on it.

The bike is a 1981 XS650 Special. Picked it up from a college kid in Duluth who wanted to start working on a Harley and needed the cash. The bike has almost 17,000 miles on it and is in real good shape. I paid $1100.

At first, I was thinking of a street tracker but I'm now heading towards a bobber build. Sprung rear end. 21"front. 16"rear. This could change at any moment. :) It changed. Straight up street tracker.

First order of business was a motorcycle lift. Picked up the one at Harbor Freight for $329. Works like a charm.

First weekend was tear down. No rush and we got it down to frame and wheels in about 6 hours. We finished off the next day, loaded everything but the engine up on the lift and put it in the corner of the shop. Engine tear down was next.


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My father-in-law, Joe the night before we begin:
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My brother-in-law, Jason and I goof around before teardown:
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Teardown begins:
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I caught it; I guess I'll keep it:
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End of the first day:
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Parts is parts:
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Joe is an engineer and designed a sweet bracket that mounts to his engine stand to make it easier to work on the engine. I'll post all the particulars of this engine bracket in another thread.

We tore the engine down and everything looked and felt great. Looks like it was ran really rich but the sandblaster took care of that build up. No need for new pistons, cylinders or valves. We honed the cylinders and seated the valves.

Engine bracket:

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Off with its head:
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It was run a bit rich:
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Pressure washing the insides with mineral spirits:
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Before and after some sandblasting:
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Blasted and polished valves:
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Blasted and beginning to polish:
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Seating the valves:
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This weekend we put it all back together!
 
Welcome to the site. Nice bike and a good buy. I see snow we got by this winter not much snow. :D Nice shop and motor stand. I would clean up the casting flaws in the ports since you have the valves out. A new cam chain and front cam guide not a bad idea. The plastic came off the guide on mine around 18000 miles. If you are not going use the crash bar I would be interested in it. I would clean the carbs and see what jets you have in it. Looks like you are having fun with it. :thumbsup:
 
Welcome. Nice photos too. Looks like you have a well equipped workshop to use there... lucky. You've made some really fast progress i have to say...
 
Thanks for the comments, kind words and suggestions.

The cam chain guide was the one thing we skipped over and didn't order. One will be on it's way soon. Thanks for everyone who mentioned it.

The build continues this weekend.
 
Back at it this past weekend. First things, first: open the box of parts from MikesXS. Everything is there except for the cam chain guide which we neglected to order. We couldn't put the engine together without the guide so we put the valve springs back on. Joe created a make-shift valve spring compressor with some copper tubing, a washer and a shop press. Works great. I polished the side covers and Joe started rebuilding the carbs.

Sunday, Joe finished up the other carb. Turns out that the floats were bottoming out because the wrong size float valve needle had been previously installed. While he was doing that I broke out the plasma cutter and grinder and went to work on lightening the frame. :) Sanded all the grinding down and primed the bare spots.

Next time we'll put the engine back together and paint the top end. We may even start mocking up the bike.


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Valve spring compressor:
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Joe gently works on the carbs:
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Looks fat:
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Weight loss:
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Have a good week!
 
Making good progress. Joe is one smart dude and innovative with it. Thanks for showing his spring compressor. I bought a press to do a crankshaft. I will be using it for valve springs now. Beats the hell out of the one I made out of a C clamp. Those side covers buffed out nicely. The frame looking really clean with all the extra junk cut off. Speaking of extra junk no sense in cluttering up Joes shop. I really need a crash bar. My bike looks a lot like the one you just took apart. The factory seat and the buckhorn bars on mine the only difference. Send me PM when you decide to unload the extras. Great build enjoying watching. I can tell this is going to be a good looker already. :thumbsup:
 
I've been slacking posting pictures. Here's a few from a couple weekends ago.

We reassembled the engine and gave it a coat of paint. It turned out great. I also drilled the front brake rotor using a pattern found on the site.

This weekend we'll start to mock up the bike and probably paint a few more pieces.

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Gently...
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The motor looks sharp . Like the black top end, silver cases and polished side covers. It will look better once you put it in the frame as a roller with the tank. The carbs cleaned up like new. Depending on the exhaust you chose then BS34 carbs not hard to tune. The 2 into 1 exhaust I would stay away from. Performance and carb tuning almost nonexistent. The 1/ 1/2" diameter 2 into 2 exhaust or the stock is the better choice. Easy to tune and performs better. The do the ton café bike is a good example of the system. Keep up the good work. Hope the snow is melting. :thumbsup:
 
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