Xs650 build thread...

krob

XS650 Enthusiast
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So after purchasing my 79 special and cruising it around last summer, I decided to tear it down and change into something a little more my style. Hoping do get the chassis mocked up and motor back in so it can be ridden more this coming summer. Then hopefully next winter I can dive into the engine and do finish work.
 

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After getting everything disassembled I detabbed the frame and shortened the rear hoop. I got a pair of shorter shocks and I'm going to drop the front a bit.

I also chopped down the stock rear fender. I didn't think it would work but I just might use it. The fender definitely needs a brace in the front. It got a bit flimsy after cutting the middle out. Not 100% on it though
 

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Can't decide on 2 or 3 inch fork drop. First pic is 2 and the second pic is 3.

Personally I like the looks of the 3 inch drop but that leaves very little suspension travel. Has anyone had major issues with a three inch drop? Going to order a spacer from hhb soon, so would like some input before I pull the trigger.
 

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Decided to go with a 3" drop. I made the homemade tools recommended by Hugh. Now just waiting on the spacers.

My seals look good from the outside...Any chance they are reusable if taken out properly? I would like to polish the lowers so they will have to come off at some point.
 

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Unless you replaced them in the near past, why would you skip putting in new seals? They are cheap, put in new ones.
 
You are right they are cheap, but mine are surprisingly in really good condition. I have read about some people having trouble when pulling the seals, so I may just leave them in and tape them off when I polish the lowers.

Turns out taking the fork apart is a 5 min job with hughs instructions, so it wouldnt be hard to replace them in the future if mine fail or I just decide to.

Im contemplating how much to chop the springs though. I did have a bit of fork sag when pulling the front brake when the bike was stock. Maybe cut the spring just 2" rather than the full 3". Is that to much of a difference? Any input on this would be great.
 
You should cut them the same length. You can also add a tad more fluid or a heavier weight. I believe 5twins says to put 7" from the top, fully compressed (without springs installed).
 
7 ounces instead of the 6 ounce spec. I'm not sure what the measurement to the level is.

You can polish the lowers with the seals in there. Just cover them like you were planning to. Many seal leaks are simply due to dirt in the seals. I think many get replaced unnecessarily. Make sure they're nice and clean when you're done and they could very well still be fine.
 
Ok so ill cut the spring 3" and add 7 oz. of oil. The extra oil will help stiffen them up. Thanks for the help, exactly what I needed.
 
Looks good!

I chopped my fender much like you did yours. I have a piece of sheet metal welded to it and curved to match the curvature of the frame to add stability. Flimsy is the right word.
 
Well haven't had much time to work on things, but I managed to polish and lower one of the forks.
 

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Forks drooped and polished. I also fastened the handle bars on to see how they would feel and look. I might change them to a flat drag bar. Any thoughts?

Next in line is to get a headlight and taillight mounted up.
 

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Got the headlight and taillight mounted. Also got a seat pan and box for electrical roughed in. Coming along slowly but surely.
 

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What are the length of those rear shocks? It appears the rear needs to come up a bit to match the front end.. Or could just be an illusion. Can't quite tell.
Looks good so far!
 
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