Everett's XS650 Revival Thread (1976 XS650C)

[everett464]

I'm a bit delinquent on this post, but - I am very likely going to try and kick this thing over for the first time this next weekend. I am almost a pure weekend warrior and pretty limited during the week; that said - depending on free-time - I may even get there tonight or tomorrow. First, before I get started, I want to say thank you to @Jim (for the excellent advice to this noob, and also for providing me with a freshly blasted and painted foot peg), @MikeyDeepXS (more advice, and for providing me with a JDM/OEM rear blinker), @650Skull (for the terrific wiring diagram), @Niels B (for attempted generosity), and @Its been a long time (for several pieces of help in my first few weeks).

I had been looking for an XS650 for several months. This was going to be my first motorcycle. See... I have never owned, or even ridden a motorcycle on an actual street before. Still, today, that is the case. I have to admit that - at 45 years old - I was honestly more interested in learning motorcycle maintenance than I was about riding (but that was before... Im now ITCHING to get this thing going). Early on I had a few bikes in mind, each being known for relative ease of maintenance, but the "classic" XS650 was the one that really called out to me. Just a sexy bike, with a cool story.

I found my bike on FB Marketplace on the morning of July 4th: a "French Blue" 1976 XS650C. Seller wanted $500 and was transparent about the bike having sat for a year after the wiring harness caught fire, but that otherwise it was mostly complete, had compression and spark, had recently rebuilt carbs, and a gas tank that wasn't totally trashed. The bike looked rough, and even had some weeds growing up and through the frame. I messaged him that I wanted it, then went to Harbor Freight, bought a wheel chock and a ramp, and borrowed a Buddy's pickup truck. My wife rolled her eyes, told me I was being dumb, and requested that I buy more life insurance.

 

[everett464]

As you can see, the bike was rough: lots of rust. I do think the vines were a nice touch. Both side covers and gas tank existed, but were pretty rough (at least from the outside.

I ordered 5 gallons of Evaporust, and got to soaking parts one at a time. In the case of the tank, I had to do it in two stages in an HDX tote. I will come back and put up a picture of the tank - but for now, here is before and after shots of the side covers.

I've now totally derusted the tank and side covers, and given them a BLO/spirit treatment. I don't know what the plan is for paint, but they will stay like this for a bit. I also treated the inside of the gas tank, but opted for WD40 (versus BLO), while I do other things...

 

[Jim]

Love the "I just stole it" grin!

Is it kick only, or does it also have the electric start?

 

[everett464]

Next I took to swapping the wiring harness. Again: I cannot emphasize how little automotive experience I have - I have changed the oil on my car exactly once, and swapped on a spare tire exactly once., and.. that's it. With that said, I am fairly handy and I really (REALLY) love figuring things out. I have done watch repair, gun maintenance and repair, electronic repair, household electric and appliance repair... My wife has accused me of being a serial hobbyist, and she is not at all wrong.

So I m not super embarrassed to say that things were a bit rough at first - it's just... daunting.

With that said, I was committed to just take it slow and work from the back of the bike forward. Swapping connection for connection. That worked for a bit, but when I got to the rectifier (a mystery box that I, at the time, did NOT know the name or function of), I suspected at least some things were amiss. PO had created some fun puzzle surprises for me.

 

[everett464]

Determined to take things back to OEM (or as close as possible, 50 years later), I picked up some connectors from Vintage Connectors, and some bad ass new tools. Honestly most of these unrelated, but pretty freaking cool. The real cool one was this Knipex ratcheting crimper that I got for a song on eBay, and that has me making perfect crimps!

Any who... I got the wiring harness fully swapped this last weekend. The headlight bucket was tedious but pretty straightforward. The rectifier took me a lot longer to figure out, as the original connector had been deleted, with wires just disappearing into the harness and stator. I, again, went slow and hammered the wiring diagram, and eventually got things more or less figured out.

A few other odds and ends: PO had deleted the main inline fuse (cool, cool, cool, cool, coooool...). I re-added the inline main fuse when I wired up the power side. I stumbled a bit at the aftermarket starter solenoid, because the wire colors were all wrong, and PO had just sort of... left it dangling on the right side of the bike. Anyway - got it all figured out, and I am basically all wired up.

Next Up: (1) reinstall fuel tank and run new fuel lines; (2) install my brand spanking new NGK plugs and caps; (3) install my new AGM battery, and... (4) probably try to kick it over.

I have incoming air and oil filters, but the oil filters are unlikely to get here this week, so I will probably change the oil and try to kick it over. Assuming I can get it running, I will change the oil again after she runs a little, because... I just found this:

 

[everett464]

Love the "I just stole it" grin!

Is it kick only, or does it also have the electric start?

Honestly, I felt like I stole it. Really a pretty exciting pickup. And, it definitely has the electric start, but unclear if anything works. You actually helped me a ton this weekend getting the starter solenoid wired up.

 

[Jim]

I have incoming air and oil filters, but the oil filters are unlikely to get here this week, so I will probably change the oil and try to kick it over. Assuming I can get it running, I will change the oil again after she runs a little, because... I just found this:

I wouldn't be concerned about all that metal... yet.
Some of these poor ol' bikes never saw a filter clean or change since they left the dealership. It's quiet possible that's what you're seeing. I'd clean the filters, stick 'em back in and add fresh oil (20-50 wet clutch compatible) and put a 100 miles on it. If there's metal then, we got a problem. My bet's on 'em coming out clean.

 

[Niels B]

looks like you are coming along steady and methodically. Have you tested the rectifier before you reinstalled it? its easily done if you have a decent multimeter with continuity. The new wiring and connectors going to save you a lot of headache, hate the crammed shit in the headlight though, and you did well installing a fuse again - may prevent a fire haha.
looking forward to the first rumble and the continuation of this tread.

 

[Niels B]

if the starter don't work it could be as simple as replacing the carbon brushes. watch out you don't strip the head when/if dismantling the starter and ensure good ground connection for the harness. I learned if its not you can have all kind of odd problems , like blinker don't blink and horn don't work, annoying, learned it the hard way - thank god for help from this group

 

[everett464]

I wouldn't be concerned about all that metal... yet.
Some of these poor ol' bikes never saw a filter clean or change since they left the dealership. It's quiet possible that's what you're seeing. I'd clean the filters, stick 'em back in and add fresh oil (20-50 wet clutch compatible) and put a 100 miles on it. If there's metal then, we got a problem. My bet's on 'em coming out clean.

Thank you for saying that, and honestly, that is what my gut was telling me (just stay calm...). The actual oil that dripped out was dark, but clean (ish), so there is some hope. As for oil - I read a LOT about what would be best, eventually settling on the 15w non-synthetic Rotella. I will probably try to start it up with that in there, but could be convinced to go a different direction once the new filters arrive (I already ordered all the filters and gaskets, they are just on the slow-boat).

looks like you are coming along steady and methodically. Have you tested the rectifier before you reinstalled it? its easily done if you have a decent multimeter with continuity. The new wiring and connectors going to save you a lot of headache, hate the crammed shit in the headlight though, and you did well installing a fuse again - may prevent a fire haha.
looking forward to the first rumble and the continuation of this tread.

Thanks Niels! And that is what I figured - get a fresh electrical start before I start monkeying around with the mechanical bits. Also, I haven't tested the rectifier, yet, but I ought to. I have a really nice multimeter, and more or less know how to use it (at least in this context). Maybe a good task for this evening...

 

[Jim]

Also, I haven't tested the rectifier, yet, but I ought to. I have a really nice multimeter, and more or less know how to use it (at least in this context). Maybe a good task for this evening...

This video I made might come in handy then.

 

[MikeyDeepXS]

PO had deleted the main inline fuse (cool, cool, cool, cool, coooool...). I re-added the inline main fuse when I wired up the power side

I was wondering why it had an electrical fire Then I read this… not such a mystery anymore


Adding a main fuse is 100% a good move!

Great work Everett! Keep at it, you’ll be on the road soon

 

[Jim]

Forgot to add... the rectifier isn't needed to make the bike run, only for charging. If it tests bad, don't sweat it, just leave it disconnected and press on trying to start it.

 

[everett464]

This video I made might come in handy then.

Awesome!!!

 

[everett464]

hate the crammed shit in the headlight though...

Niels - This comment was giving me some pause. I had sort of assumed that this is just how it goes... Is there a way that I should be addressing this now, short of installing an M-Unit or something (which is maybe on my distant ish horizon)?

 

[Jim]

I call it the spaghetti monster. No, there's no other way. It's messy, that's just the way it is.

 

[650Skull]

Niels - This comment was giving me some pause. I had sort of assumed that this is just how it goes... Is there a way that I should be addressing this now, short of installing an M-Unit or something (which is maybe on my distant ish horizon)?

The 76 has a lot less wiring than an 80 with the same headlight bucket size
It can b made to fit in if you take the time to untangle the wiring.
This involves twisting the plastic connecters so all the wiring is more uniform. It is then a case of laying it in the bucket around it, more than to the back, where the clip for the headlight leaves little room behind the lens.

My 80SG after a lot of tidying up.

 

[Niels B]

I call it the spaghetti monster. No, there's no other way. It's messy, that's just the way it is.

As Jim says - it’s just a mess. Someone here suggested to paint the inside white - and it actually gives it some sort ease to identify the various wires

 

[everett464]

The 76 has a lot less wiring than an 80 with the same headlight bucket size
It can b made to fit in if you take the time to untangle the wiring.
This involves twisting the plastic connecters so all the wiring is more uniform. It is then a case of laying it in the bucket around it, more than to the back, where the clip for the headlight leaves little room behind the lens.

My 80SG after a lot of tidying up.
Pic in this link.
Having bad internet day, can't load pics so this link should do it
https://www.xs650.com/attachments/dscf7015-2-copyright-jpg.340549/

Oh that IS nice!

 

[everett464]

This video I made might come in handy then.

Happy to say everything was very consistent in both directions and in both diode and resistance modes (much closer than your video, Jim).