1981 XS650 Project Something or other (going cafe-ish)

I have this build going over on xs650.com, but I really enjoy this site, and it seems to get more participation due to the number of different styles of builds and bike brands, so I'm posting here too. I'm not really following any particular style per say, I like aspects of both café and brat/tracker styles. The bike Is going to have a longish, thinish, seat, ala the brat style, a mono shock rear suspension that, if everything works out will be pretty unique, either clip ons or drag bars and a little flavor here and there.

So far I've rebuilt the motor, have front and rear wheels and hubs at the powder coater, the fork lowers and triple trees are also out for powder. For the wheels, the front is 21", rear is 19" both spoke, rear is a stock drum brake, front will get an FZR 600 upgrade to the disc and caliper. For the tank, I have one from an RD400 and a Ducati Cadet, still deciding on which one I'll go with. As the frame gets further along in the fabrication process I'll throw them on and see what sticks. I really like the look of the RD400 tank but the thing is huge, I may end up shortening it a bit.

So enough of the boring words, on with the pics...

Re: 1981 XS650 Project "Something or other"

This is how it started, bought it off a buddy at work for $600, it ran but not great and had quite a few leaks around the motor. The bike had just over 21,000 miles on it.



Started the tear down and it became apparent the bike had been around some moisture at some point.



For the most part this is how the frame looks now



For the exhaust I had Gordon Scott Engineering build me these 2 into 1 that run under the bike, down the right side so I still have access to the drain plugs. Still not sure about the muffler or how and where the exhaust will end.

Re: 1981 XS650 Project "Something or other"

I decided to do a complete rebuild of the motor, didn't want to put a bunch of time and effort into building a nice bike only to have the motor crap out.

Started with the carbs, soda blasted the bodies and bowls, and threw the small pieces, jets, needles and such in the ultrasound cleaner. When they were all cleaned up I painted the bodies and bowls and had the linkage pieces, top cover and brackets powder coated. Put them back together with new gaskets, o rings and rubber bits, new float needles and set the float height.





After soda blast





New float needles and rubber plugs, float installed and height set





Parts back from powder coat and assembly finished











A little goodness from Steel Dragon Performance

Re: 1981 XS650 Project Something or other

Tore into the motor next, the innards were in excellent condition, the only hiccup was the cylinders had corrosion form water sitting in them. After weighing out the cost of boring the cylinders, having to buy oversized pistons and rings, I decided to try to find a good clean set of cylinders. Luckily I was able to do just that, for cheap! So a quick hone and a new set of rings and I was set to go.

Tore the motor down completely, split the cases, glass bead and soda blasted everything, had the head rebuilt, painted the cases, jugs and heads, had the head cover, tappet covers and breather powder coated then put it all back together.









Cleaned everything and put some color on









Starter delete mod (car engine freeze plug)



Cleaned everything again with brake cleaner, chased all holes (with a little help) and blew it all out with compressed air getting ready for assembly.





Installed the shifter forks on the selector drum and dropped the tranny back in.

Re: 1981 XS650 Project Something or other

Got the motor back together, everything went very smoothly, and I think it looks pretty good.







Gave the cylinders a light hone, gapped the rings and slid jugs on











Went ahead and dropped head on and mocked the rest of the top end up. I'll get the cam in and torque everything down when I get some more time

Re: 1981 XS650 Project Something or other

great job, looks the goods

Re: 1981 XS650 Project Something or other

Nice, you almost make it look easy.

Re: 1981 XS650 Project Something or other

That is one good looking motor!!! Great job.

Re: 1981 XS650 Project Something or other

Thank you pjdave, Tijmen and cyclefreak for the compliments. Tijmen, the assembly actually did go pretty easy but there was 3-4 months working up to that with, de-greasing, blasting, painting, powder coating and just waiting for parts. That did give me a ton of time to do research and cruise this and other forums for good tips and tricks. SO much good info on the interweb.

So there's 2 powder coaters in town and they're both running 2-3 weeks behind and I have stuff at both of them. I really need my rear wheel to get done so I can lace it up and start mocking up the rear end, until then I'm kind of at a standstill. To keep busy and give myself some sense of progress I've just been cleaning and blasting little bits and pieces and finalizing some small design ideas. I did manage to pick up a steal on EBay, an entire dual disc brake set up from an FZR 600 for $27! I was pretty stoked about that. Also waiting on an order from McMaster Carr and a seat hoop to show up. To keep myself busy I'll go get some scrap metal and practice my welds and just keep doing the little things until I can get stuff back from powder and move forward. It's hard to wait and frustrating, want to get going on the bike!!

These are the tires I'll be running, Kenda K761. I love dual sport tires, both the look and the functionality and Kenda had them available in 21" front and 19" rear.






So now, I just sits and waits....sucks!

Re: 1981 XS650 Project Something or other

Opinions please. Just looking for thoughts on the different shapes for now, when I get the rear sub frame mocked up I'll ask for opinions again.

Re: 1981 XS650 Project Something or other

Very impressive work, engine looks great! Personally I'd go with the RD tank but then I don't have a clue what you have in your head for the overall look. Can't for the life of me see how a 21" front wheel is going to get worked in there but you have a vision, only bike I see needing a 21" front is a motocrosser.

Re: 1981 XS650 Project Something or other

johnu said:

Very impressive work, engine looks great! Personally I'd go with the RD tank but then I don't have a clue what you have in your head for the overall look. Can't for the life of me see how a 21" front wheel is going to get worked in there but you have a vision, only bike I see needing a 21" front is a motocrosser.

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That's exactly what I have johnu, a vision. Whether I can create that vision is a whole other story, and if I can, whether or not it looks like complete ass is another. I got some 1/4 inch round bar scrap yesterday so I can start mocking up the rear frame section. When I get that done and if it doesn't look like complete shit then we'll ALL get to see my vision.
The seat is going to look something like this...different bike of course

http://www.dotheton.com/forum/index.php?action=dlattach;topic=51740.0;attach=101261;image

Re: 1981 XS650 Project Something or other

Very cool. Id go w the Bridgestone (???) tank. The RD tank is looooong.

Re: 1981 XS650 Project Something or other

VonYinzer said:

Very cool. Id go w the Bridgestone (???) tank. The RD tank is looooong.

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That's definitely something I would do if I used the RD tank is shorten it a bit. Probably narrow it a bit too, it's a BIG tank. Just for info, the other tank is off a Ducati Cadet. That one may be a little too tall on the rear end...I may just end up with a totally different tank when all is said and done, who knows. I like the shape and size of a lot of the 70's smaller cc Kawasaki bikes

Re: 1981 XS650 Project Something or other

Please please please please dont cut up the RD tank. Haha. They just keep getting harder and harder to find (ask me how I know...)

Re: 1981 XS650 Project Something or other

Copy that

Re: 1981 XS650 Project Something or other

Still waiting for parts from powder, while I do, I've just been doing little things and picking up some parts getting ready for fab to start on the frame this weekend.

Picked up 2 hoops from SONIC



Considering these two tanks as another alternative to the RD and Ducati tank. Both need some work but I like the shape of them. Opinions please...

Re: 1981 XS650 Project Something or other

Got a new addition to the shop, two friends and I went in on a Miller Millermatic 140. We all have projects but were too cheap to buy our own welder, we all live close and it's small enough to switch locations with ease. One friend has a large pole building/shop that it will live at most of the time but for now it's in my garage ;D



Also bought a tank today

Re: 1981 XS650 Project Something or other

billyp said:

Still waiting for parts from powder, while I do, I've just been doing little things and picking up some parts getting ready for fab to start on the frame this weekend.

Pick up 2 hoops from SONIC

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Hey Billy, I'm looking for a hoop like this! Can you point me in the right direction?

Re: 1981 XS650 Project Something or other

Enginerd77 said:

Hey Billy, I'm looking for a hoop like this! Can you point me in the right direction?

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http://www.dotheton.com/forum/index.php?topic=54894.0