XS Built for fun...

Sho-TymeXS

XS650 Enthusiast
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Well, I've been messing around with XS650's for awhile now. Built a few with friends and started a few builds that got sold before finished. So I've been itching to finally build one for myself. Not to anyone else's standards or liking (too many build for customers). This itch went on for about 5 years as life continued to get in the way.
Last winter I picked up a KTM 125SX dirtbike frontend (with no bike to put it on in sight), and stored it away with several other parts I'd found at a deal to good to pass up.
It wasn't until about 2 months ago a 1983 XS feel into my lap for next to nothing. So here I go. Time to build the dike (one of the bikes) I've been dreaming about. Something to have fun on, ride hard, and simply enjoy without worries of extremely costly repairs like my 99 Harley Road King.
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So once I got a lil time I dove right in removing everything that was obviously unnecessary. All safety switches/relays, turn signals, etc. Still have to finish sorting thru the wiring but I'll get back to that one I know more about the direction this build is going to take me.
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First challenge, fitting the KTM frontend to the XS neck... I thought long and hard after taking some initial measurements and test fitting.
It turned out that the new steering stem had a different O.D. than the XS... at the top (27mm[KTM] vs 25mm[XS]) at the bottom(27mm[KTM] vs 30mm[XS]), but once pressed out of the lower tree the KTM bottom O.D. went to 30mm. The KTM stem was also 16mm shorter than the XS. So... I decided to have the lower KTM tree stem seat bored 16mm deeper. Thus allowing for stock XS bearing on the bottom and also giving me the length to the top tree I needed. I also had the KTM stem turned down to 25mm from top to upper bearing seat height.
Lucky for me I work at a full fledged fab shop so I bought a machinist at work lunch to get the job done and did the pressing out and in of the stem myself.
 

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After machining... I forgot to get a pic of the stem b4
 

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It mounted like a dream... So far so good. The forks will need rebuilt later (leaking seals) and I figure I'll change the springs/spring rate or install a pvc spacer. It will depend on budget when I get to that point LOL. As for now the KTM frontend is mounted and on to the next... Rear wheel and suspension.
 

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Found a CB400TT gas tank in my stash that I modified for practice several years ago. I think it fits the build better than the stock tank but might not have enough fuel capacity in the long run. But for now it will do.
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Since this bike will be seeing both on and off road use I'd like to go with dual sport or flat track tires. At first I was going to go with 19" wheels front and back but after searching tires I found that 19" rear tires wider that 110 are hard to find and it don't want that slim of a tie in the rear. So 18" or 17" seemed to have the most tires available in the 130 - 150 range.
I found a 18" x 3.5" rear rim laced to a 77-78 KZ1000 hub at a local used motorcycle parts store and managed to do some trading of parts I don't need in exchange for the wheel.
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I'll go sometime this week and pick up a cush drive and sprocket for it. Couldn't wait to get it home and mock it up. It came with a 170 tire on it but that's bigger than I want to run and week swap for a 150 or 140 soon.
As you can tell in the pictures that KTM frontend is much taller than stock. So a stretched swingarm is in need.
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Leveled it out pretty good with some jacks. I'll figure my rake and trail in that position sometime this week.
Slapped parts lying around on it just to get a better vision ...
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Got the extra swingarm I had blasted at work to make stretching easier/cleaner. Here is ever I have a question.

Does anyone know that size the I.D. of the swingarm tubes happen to be our what O.D. tubing did you use as plugs when stretching?

I'm thinking either 4" - 6" stretch. Not sure if I'm doing a mono shock or dual socks. For some reason I want to go with a dual shock.
 

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Cool. An elevated backroads dirt-burner.
Yes, that tank looks good on there.
Your cush drive setup should be interesting.

Sorry, can't help with swingarm tubing ID.
 
Cool. An elevated backroads dirt-burner.
Yes, that tank looks good on there.
Your cush drive setup should be interesting.

Sorry, can't help with swingarm tubing ID.
Right on! I wasn't sure if I would go cush or direct drive. If it doesn't go well I'll get a YZ hub and lace the rim to that.
I like this hub cuz it's disc brake and takes a 20mm axle.
 
I've been going back and forth between dual shocks, old style mono shock, our new style mono shock.
Dual shock... Will work with some shock relocation, but socks will be where I'd like to run my exhaust.
Old style mono shock... Added weight and extra fab work, but makes room for exhaust.
New style mono shock... Reduces weight, allows for use of tunable nitro shock, but a lot of math to get the rebound and preload correct.

Still scratching my head as to which route will be best for this build. Opinions, design idea,
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please?
 
I'm sure it is something I'm not seeing or understanding but won't your chain be gnawing on the top of the swingarm?
 
Finally Got some time to get back to it. decided on a 8" stretch. sounds really long but that's the number i came up with to level the bike out.
 

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Looks like it's going to work out pretty well once overbraced. Since it's so long I decided to go with an old style mono shock.
 

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Man, those are stout looking forks on that 650 and one other thing is for sure....you'll be the only guy riding in the dirt with such a nice cushy looking seat!
 
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