XS 850 Re Model

The mould turned out ok ,but I was too mean with the PVA or forgot to apply it to one side any how I wrecked the paint on the tail piece. The owner was not bothered and asked if I would make him one from my mould. The blue one is for him.There was some bubbling of the gel coat in one place I think it was to thin but will talk to a local who has been doing this stuff for years to find the fix.
The next one out of the mould will be for the 850 and will be wider and not have gel coat as I want to lay the seat pan up to it. 20230514_164651.jpg20230514_164700.jpg20230514_164711.jpg
 
I have been side tracked a bit working on the RD ignition but was able to make the rear exhaust bracket. It needs welding at the bends but I am out of gas at the present. I also have started making the RHS foot peg hanger rear brake master cylinder mount. Wish I had a band saw.
Slowly making progress but another interesting project is looming so this will go on the back burner for a while. As Jim says the 850 will glare at me when I go in the shed.
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Hi. Just looking to see if there were any updates and pics on this thread.
I have a similar XS850 project underway, looking at R6 front end, 80’s cafe look to it.
You said you fitted the rear R1 calliper bracket with only a slight mod and the xs disc. Can you enlighten me as the R1 disc is smaller.
Cheers.
 
Hi Eugene, it has been such a long time since I did this I am struggling to remember. I did make a large spacer to bring the XS disc out further, and drilled the new hanger to suit the larger 850 axle.
I cant remember what year the caliper and hanger came off but if you look at post number 18 you can see it has a casting for a torque arm. Most of the ones that come up in google images dont have this casting.
From memory all I did was drill the casting, move the disc to compensate for the off set and make a torque arm that fitted to the XS rear brake hanger bracket mount.
I don't remember having to compensate for the R1 having a smaller disc.
 
Hi Eugene, it has been such a long time since I did this I am struggling to remember. I did make a large spacer to bring the XS disc out further, and drilled the new hanger to suit the larger 850 axle.
I cant remember what year the caliper and hanger came off but if you look at post number 18 you can see it has a casting for a torque arm. Most of the ones that come up in google images dont have this casting.
From memory all I did was drill the casting, move the disc to compensate for the off set and make a torque arm that fitted to the XS rear brake hanger bracket mount.
I don't remember having to compensate for the R1 having a smaller disc.
Thanks for the info. I just can’t find any hangers for a larger 265mm disc only the 1998 R1 at 245mm, was considering getting the XS disc turned down.
Nice work you’ve done there, are you keeping the wire wheels?
 
Thank you and yes I will keep the wire wheels. They came with the package of 1 bike and 1 parts bike I bought. They are from a Japanese market GX 750 that was not sold in NZ and pretty rare. They have been rebuilt with new rims and spokes. The cost was eye watering.
 
That’s a shame. Yes, they are like rocking horse poo. But the bike looks the absolute business with wire wheels. I’m looking into getting a one off hub done , but like wise it gives me heartburn.
 
For the front use a wire wheel XS 650 hub. For the rear a friend of mine's son got a rear hub from a XV500 virago (some models had wire wheels) for his XV500. No idea if it would fit an 850 rear drive but given that a lot of parts do interchange it could be worth researching.
Check the part numbers on CSML might give you a clue
 
Update on previous question. For anyone else looking at fitting BlueSpot rear calliper.
I’ve sourced bracket and calliper.
XJR1300 rear hanger and bluespot to fit.
FZR1000 also uses same calliper.
Bracket off this model hangs wrong way around in my opinion.
The R1 bluespot will not fit,too small c to c on mounting bolts, nor is the hanger suitable.
Spacers required to bring disc out by about 10mm and spacer required to make spindle correct diameter for XJR bracket.
I’ve just used a square ally arm to hold calliper in position.
Think that’s it. Just need to rebuild bike now 😖.
 

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The rear caliper I have must be from an XJR1300 as it looks the same as yours. I am sorry if the incorrect information I posted sent you on a wild goose chase.
I haven't been back at this bike for a while I will post updates when I do.
Are you going to start a thread for your 850?
 
The rear caliper I have must be from an XJR1300 as it looks the same as yours. I am sorry if the incorrect information I posted sent you on a wild goose chase.
I haven't been back at this bike for a while I will post updates when I do.
Are you going to start a thread for your 850?
No apologies needed my friend.
If it wasn’t for your post I wouldn’t have given it a thought. The research is always interesting.
Both callipers look the same/identical. Only difference is the size. The only big problem is availability, the R1 calliper is quite common and well priced, the XJR calliper is like rocking horse poo and at least double the price £200 +++
I’ll probably do a finished build on the XS850 site, if I ever get there 🤣. I’ve had so many hold ups, one being the engineers I use. Their workshop complex went up in flames and a lot of my stuff was trapped inside for months and I lost a bit of interest at that point. But we’re on the move again now.
 

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Wow lucky you got your parts back. I got fed up waiting for parts to be made by professionals. They were invariably wrong so I bought a mill and with no experience got stuck in. I made lots of mistakes but also made some useable stuff as well. If you are in a position to do so I highly recommend getting your own machines.
I hope your 850 project goes more smoothly from now on.
 
The stuff of dreams. I’ve got a small lathe and have done all the small aluminium bits, rear wheel and disc spacers etc, It’s a start.
Thanks for your help, I will post a picture when done.
 
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