Just a few tweaks to get it running :-) ........got a bit carried away !!! XS650 Makeover

  1. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Hello All,

    Finally got round to starting a thread on my "quick" turnaround bike project that I find myself with......

    I have been working on another bike build in another thread on this forum for the last couple of winters but got a little side tracked and started to lose my way a bit with it https://www.mig-welding.co.uk/forum/threads/anyone-for-cafe-here-we-go-again.68714/#post-906826
    So rather than rush things I decided towards the end of last Spring to put it on hold for a bit, and get a "runner" just to have a bit of fun on, in the long but forgotten Summer of 2018.

    Always fancied a "tracker" style project so back in Feb last year, up popped a reasonably priced 1976 Yamaha XS650, from that not forgotten Summer of '76. It was a runner................back in 2015, the last time it was on the road :laughing:. So after convincing her indoors of the virtues of acquiring another "appreciating" classic..............well I appreciate it anyway. Off I went with the trailer to collect another.

    I've been working on it for a few months since the end of spring last year, so I'll post some pics up just to start things off and pop in now and again with some the progress.................dumping a few hundred pics on the forum in one go will take more time than building the damn thing.....anyway on with the build.

    As you can see it wasn't in too bad a condition, someone had made a decent job of a tracker custom job a few years back so unlike me previous builds I had a decent starting point. Quick look over, quick service and Id have the summer to ride it..........so I thought !!:whistle:
     
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  2. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    First job was to get it running.....................errmm. It was two years previous according to the previous owner, but I could not start it!!! Quick investigation reavled a weak spark and lack of fuel. As i wanted something fairly relaible I invested in a contactless points system and set about fitting that, along with a quick look in the carbs:o

    And no...........that is not a colour problem with the camera, they were literally green inside:whistle:
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  3. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
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    As I dug deeper and deeper under the skin It dawned on me this was'nt going to be a "quick" makeover:doh:

    The wiring was atrocious and when I pulled off the clock mounting and saw it was made from an old road sign I knew this was about to get messy and..............expensive !!!:whistle:


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  4. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Finally got it running.......bit rough but it was running :thumbup:..............

    As Id already decided to get a little bit more involved than getting it running I did some research and started the usual Ebay trawl for bits and bobs.........first up was a rare hard to get hold of "how much!" DT400 tank. So threw that on along with GRP seat unit I fancied the look of.

    The tank had seen some action in its previous life and looked like it had been run over by a bus :whistle:

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  5. eLuSiVeMiTe

    eLuSiVeMiTe Forum Supporter

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    8,547
    Location:
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    Nice project.

    Be worth it in the end.
     
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  6. roofman

    roofman Purveyor of fine English buckets and mops

    Messages:
    6,365
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    :thumbup::thumbup:
     
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  7. pedrobedro

    pedrobedro Man at Matalan

    Messages:
    9,792
    Location:
    CX Derbyshire
    I did a Divvy and the carbs were worse than that, all the jets had practically dissolved and they smelt like old gloss paint. I had to replace them completely.
     
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  8. Tifa

    Tifa Member

    Messages:
    23
    Location:
    Shropshire
    Subscribed!

    That exhaust wrap has got to go.
    (We all know the headers under that crap are rusty/dented/bodged/poorly welded don't we?)
     
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  9. frank horton

    frank horton V twins are great but 4"s rule.........

    Messages:
    1,348
    Location:
    Soon 2 B Crete
    funny how thw quicky jobs just get outta hand.........nice one......
    1 good run in the sun, u'll forget all the probs........
     
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  10. pod70 Member

    Messages:
    87
    Location:
    Kent, England
    We've all been there. I have a few projects that were just going to get a quick tidy up. Great bikes the XS650 - had a hardtailed chop for a while (that was bought as a runner and ended up stripped & rebuilt once I discovered the various horrors such as threaded bar for the engine bolts, numerous stripped threads and the inevitable twisted together wiring loom)
     
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  11. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Right, time to get the grinder fired up:o......as soon as this tool showed up I knew it was the point of no return:D.

    The replacement seat GRP moulding did not quite sit on the frame where I like to off with the existing rear hoop

    Next up for the "treatment" was the battery box, once Id fished out all the cables randomly taped and cable tied here and there...

    Seat and tank now sitting at better positions on the frame :thumbup:

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  12. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Next up was a quick mockup of the exhaust. Id decided to get an off the shelf set of headers from Delkevic and then use a random silencer I had lying around. The price of the headers was a fraction of the cost of buying mandrel bends, collectors etc, so went with with it. Only thing I dont like is the pressed collector. I'll probably tidy it up later by grinding off the seams and welding it flush.

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  13. Kayos

    Kayos Member

    Messages:
    4,714
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    Yorkshire
    I love your threads, the keep a committed non biker interested
     
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  14. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Needed to work out how to secure the seat unit to the frame and minimise the amount of fasteners required to hold it in place. Bit of angle with some slots cut out along with a pair of aluminium bobbins through the seat sorted it. The front is going to be secured with a thumb screw under the tank mounting bracket.
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  15. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Back to the rear hoop Id cut off......

    I needed somewhere to store all of the electrical bits and bobs along with trying to tie both sides of the rear frame together. Coupled with the fact I didn't want any bits of frame showing, so ordered some tube and managed to get a decent bend with my old Hilmor manual bender. Welded in place it gave me something to try and build a rear tray out of, whilst keeping things tucked away.

    Made a nice little cardboard battery and set about trying to hide this. There are smaller batteries available but I had one there off a previous bike and decided to use that originally....but stumbled across another battery I had lying around so ended up making a Mk2 cardboard version at a later date....when the bike is on the ground it is hardly noticeable.

    The year the bike was made it comes with both an electric and kick starter. So to save my skinny legs I decided to use the power of electrickery !!! :whistle:
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  16. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    The other battery I picked needed somewhere to live so set about making a box I could attach it to the frame.
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  17. magicgrotto Member

    Messages:
    79
    Location:
    doncaster
    Keep up the good work :)
     
  18. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Back to the rear again, and hoop #2 :D

    Thinking further ahead and wanting to loose the rear mudguard I knocked up another hoop, and again trying to hide it from side view managed to squeeze it in under the GRP seat moulding

    All that work just for the starter solenoid and igniter :whistle:...........................which later ended up somewhere else :doh:

    At least I had somewhere to hang the tail light :thumbup:
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  19. zx9

    zx9 Member

    Messages:
    3,413
    Location:
    South East London
    I never thought of laying a battery down like that, I assume it must be a gel / glass mat type?
     
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  20. lchris21

    lchris21 Member

    Messages:
    1,182
    Location:
    South Wales
    Back to the tank.................

    As it was just sitting loosely on the frame I need to fix it in position whilst maintaining the lines I wanted, this meant sitting it as low as possible to the engine. Unfortunately the tunnel in the tank is a lot narrower than the original XS set up so I had to get creative.......

    Cut the tank and give myself a lot of headaches welding it back up or just trim the enginge mounting bosses a tad?

    There was plenty of meat on the head casting so knocked up my own spot facing tool from a bit of HSS and length of steel rod to machine the head in-situ...

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