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Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: Rat_ranger on Feb 19, 2017, 18:10:23

Title: xs650 Sumotrack
Post by: Rat_ranger on Feb 19, 2017, 18:10:23
Ok, I just picked up a 78 xs650 yesterday for $100.  Plans are to make a street tracker.  It will get an fzr400 3tj swingarm and monoshock as I already have the swingarm.  I actually have 2 of them.  Probably get a set of USD forks, I do want spoked wheels on it. 

Engine will be kick only, at some point I want to rephase for the sound. 
Title: Re: xs650 tracker
Post by: Rat_ranger on Feb 23, 2017, 19:39:24
1st step is to fix the reason it was parked over 10 years ago.  So rather than fix the stock charging system I am upgrading to a PMA set up.  Parts are coming in so last night at work I went over to the waterjet and made the mount plate to use a banshee stator mount.
Title: Re: xs650 tracker
Post by: Rat_ranger on Feb 26, 2017, 00:30:13
Some progress was made today.  First did an actual compression test 110psi on both cylinders.  Carbs are cleaned and installed.  Exhaust was removed, banshee flywheel lightened in my lathe and thats where I stopped.  Ordered a flywheel puller as the right one is cheaper than a 3 jaw locally.  So now to look over the manual that arrived, clean and set the points and get ready to finish the PMA conversion.
Title: Re: xs650 tracker
Post by: Rat_ranger on Mar 11, 2017, 16:45:13
Small update, finished the PMA swap, put some fuel in the carbs and it fired on the second kick.
Title: Re: xs650 tracker
Post by: Rat_ranger on Mar 18, 2017, 12:46:58
Did some work on the bike when the sun came out the other day.   Complete different look in a couple hours.
Title: Re: xs650 tracker
Post by: Rat_ranger on Mar 31, 2017, 17:51:58
New swingarm fits.  It ia from a fzr400rr 3tj.  Aluminum, beefy and lightweight.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 19, 2017, 19:46:38
Need to get a few pictures, but zx6r forks are on the way, CB550 front hub has started the machine work to be used with the big piston forks.  Intake manifolds for the EFI conversion are started, need to do some layout and get them on a mill. 
 
Finally I decided to call this the Sumotrack.  Reason being is it will have street tracker styling, but it will have fairly modern suspension with 17" wheels.
Title: Re: xs650 Sumotrack
Post by: VonYinzer on Apr 19, 2017, 22:33:14
Following along. Neat stuff!
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 20, 2017, 13:20:00
Thanks, it'll probably take a while since the money for parts comes from overtime.  But having a lathe there are some parts that will be made from material out of the scrap pile, like the intakes.
Title: Re: xs650 Sumotrack
Post by: canyoncarver on Apr 20, 2017, 13:28:49
Neat.
Title: Re: xs650 Sumotrack
Post by: Eleganten on Apr 21, 2017, 19:03:05
Looking forward to seeing this one roll! Dose the swing arm or frame require any modification to fit, except the shock mount?


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Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 21, 2017, 23:18:08
I had to remove 10mm from each side of the swingarm.  A standard US spec 1990 fzr400 swingarm would be simplest as the frame would need 5mm removed on each side.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 28, 2017, 15:50:02
So one side of the hub adapter is almost complete.  Just needs the holes drilled and tapped for bolts.  And the forks arrived, once I finish the hub I will probably make a new stem to use the xs bearings rather than trying to mix and match.
Title: Re: xs650 Sumotrack
Post by: danejurrous on Apr 28, 2017, 15:55:13
Yeah, definitely following this one..
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 29, 2017, 17:41:47
Just need to drill and tap a few holes and the cb550 front hub will use the bearings and spacers from a 2012 zx6r, and a ducati rotor.
Title: Re: xs650 Sumotrack
Post by: Popeye SXM on Apr 29, 2017, 19:06:17
I'm in
I like what you'r doing. Keep posting us pics
Title: Re: xs650 Sumotrack
Post by: Supergyro on Apr 29, 2017, 21:53:54
Looks like you've got a solid plan. In.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 30, 2017, 01:36:20
Thanks for the interest everyone.  I run CNC mills for work and my little atlas lathe is how I stay in practice on manual machining.  I picked it up about 2 years ago for $500 and it was a steal.  It is big enough to be fairly capable, but depth of cut is limited so progress can be slow. 

 You don't need big and fancy to get good results, patience and working within the machines limits does the trick. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 02, 2017, 13:30:29
It appears I made the hub adapters right.  Zx6 bearings and spacers, ducati rotor, r6 caliper and it all lines up.  I'm pretty happy since the one rotor to rotor measurement I could find online was probably done with a tape measure and the rest was based off measuring the bearings, seals, and internal spacer.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 12, 2017, 13:25:53
Seems I now have a kawasaki front end on an old yamaha.
Title: Re: xs650 Sumotrack
Post by: doc_rot on May 12, 2017, 14:42:27
nice work
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 12, 2017, 15:45:32
Thanks, I'm trying to do everything right on this one to make up for all the hacking I did when I was younger.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 13, 2017, 18:14:30
Here is a detail piece for the front end.  An aluminum cap to seal the tapered bearings from dirt.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 23, 2017, 00:31:10
Slowly working on it.  Just changed jobs, so hopefully more money coming in unless the wife manages to spend me into the poor house.
Title: Re: xs650 Sumotrack
Post by: Ryan Stecken on May 23, 2017, 04:11:13
Im in Sir.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 25, 2017, 20:46:48
Well my tank made it.  It is even pretty close to fitting.  It is literally just slid onto the stock front mounts in the picture.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 27, 2017, 18:11:00
No progress today, between weather changes, the new schedule that is opposite of my old one and feeling under the weather I haven't done much.  But today I used all of my energy moving this into my garage.
Title: Re: xs650 Sumotrack
Post by: Bone91 on May 29, 2017, 19:53:22
Keep it comin 👌

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Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 21, 2017, 22:26:24
Slight progress.  Working on a lazer style triple clamp set up.
Title: Re: xs650 Sumotrack
Post by: canyoncarver on Jun 21, 2017, 22:40:16
Excellent stuff.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 23, 2017, 23:22:52
Just about ready to start the lathe work on the triple clamps.
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Jun 24, 2017, 01:35:37
Nice work!
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 24, 2017, 18:50:09
Thanks, I'm enjoying the build process.  I just wish I could finish faster and get to riding.
Title: Re: xs650 Sumotrack
Post by: Popeye SXM on Jun 24, 2017, 22:18:04
Take your time. The more satisfying the build the more fun the ride afterwards.I hate it when I think if only I had done that part better. Great build so far  ;)
Title: Re: xs650 Sumotrack
Post by: JAGspeed on Jun 25, 2017, 00:11:21
Looks great so far! I built a XS650 single shock tracker that I still ride all the time one of my favorites. I would love to do a rephase also but haven't had the time. What other engine mods do you plan on?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 25, 2017, 02:11:44
Biggest engine mod I plan is going microsquirt.  It'll cost about the same as a pamco and a set of flat slides.  But othwerwise I'm tempted to get the high ratio primary, OD 5th, rephase and 700-750 bore.  But it all takes time and money.  So at first I may be pretty darn stock on the engine and spend the money to revalve/spring the suspension.
Title: Re: xs650 Sumotrack
Post by: JAGspeed on Jun 25, 2017, 11:32:27
I have a Pamco w/ign. advance on my bike works great. The microsquirt would be nice.  I used a set of Ninja 500 CVK carbs on my bike after rejetting them they work great really smooth power and drivability with this set up. I had a set of flat slides from Mike's XS on there originally but they are junk never could get them dialed in.
Title: Re: xs650 Sumotrack
Post by: teledan on Jun 28, 2017, 12:14:13
Awesome!  love your old Atlas lathe.  I've got a 6" Craftsman badged Atlas and it's a blast. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 28, 2017, 22:37:06
Yeah, in general in not a carb guy.  My 73 triumph spitfire is running megasquirt 2 with individual throttle bodies.

  Thanks, I've really gotten a lot of use out of the old atlas, at times I wish I had a bigger lathe so I could do more depth of cut and finish faster.  But work with what you have, it'll do great if you take your time.

A little progress today, contemplating possible upper shock mount.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 04, 2017, 15:58:36
No more jack stands.  It is now on normal bike stands front and rear with the rear shock supporting weight.
Title: Re: xs650 Sumotrack
Post by: JadusMotorcycleParts on Jul 24, 2017, 17:21:08
I like where this is going...
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 24, 2017, 20:43:28
Thanks!

Not much of an update, but rear wheel is on with spacers, need to make a rotor spacer.

But I've been temporarily sidetracked finishing my tube bender so that I cane make the seat frame.
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Jul 24, 2017, 21:27:44
I am keen to see your finished tube bender.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 24, 2017, 21:36:40
It is a copy od the JD2 bender.  Found the print here http://chopperhandbook.com/bender.htm .  From that I made a DXF and cut it out on the waterjet at work.  I'm boring the 1" hole to 1.25 and turning an aluminum bronze bushing that will keep the inside and outside arms together when swapping dies.  The bushing will also hopefully make the action a little smoother.
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Jul 24, 2017, 21:41:53
Thanks for posting that.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 24, 2017, 21:43:13
Your welcome.  I'm all for sharing useful information.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 25, 2017, 22:14:14
Update on the bender.  Main pivot holes are bored to 1.25" and aluminum bronze bushings are turned and fitted.  1" 3.5 clr die set will be here monday.  Now to finish the stand and make some spacers.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 29, 2017, 19:36:52
Die should be here monday.  So this thing is getting pretty close.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Aug 19, 2017, 19:46:19
Tube bender is basically finished, just a few details to clean up.  But it can bend as is. 
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Aug 21, 2017, 15:59:10
Cool!
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Aug 22, 2017, 00:18:21
Thanks, I'm using the trailer jack because hydro is expensive and I didn't want ro have to anchor it.  The lwgs fold up so that it stores small.  Fancy part is the harbor freight digital angle finder modified to be a digital read out. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Aug 25, 2017, 23:24:49
Well, I have handlebars now.  Upper triple needs some finish work, but it fits!.  Bars are protaper dirt track bend.  I'll look at trimming them to length once the seat is mounted and I can sit on it.  Ordered a smaller centerline radius die for the tube bender, the I have just won't look right for the seat frame.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 03, 2017, 21:40:43
Well got my 3" CLR die for the bender, and with the DRO I can now repeatably make seat tubes.  Specifically for the champion style flat track seat.  I actually called and emailed a few different frame builders about buying just this piece and never got a call or email back.  So if anyone else wants a tube bent for this style seat let me know.  If there is interest I could do a small run.  Sorry the pictures aren't great, I'll get some better ones once I get it on the bike.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 03, 2017, 22:54:18
Propped in place to get an idea of how it'll look.
Title: Re: xs650 Sumotrack
Post by: Pinky23 on Sep 04, 2017, 15:03:47
Awesome work man


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Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 04, 2017, 17:53:00
Thanks! I feel like I'm making progress, but I know soon I will fall into the waiting on money holding pattern. 

Hubs were dropped off to be laced.  I'm going with a 17x4.25 rear and a 17x3.5 front.  I'm too chicken to really push a bike on the street, but this will let me have a huge selection of tires. 

Seat tube is on the bike at an angle that will match the tank, over the next week I hope to finish the bracing on the back of the frame. 
Title: Re: xs650 Sumotrack
Post by: pacomotorstuff on Sep 05, 2017, 09:18:49
XLNT tube work on the rear frame loop - could have used your talents a couple of years ago when I was building the my tracker LOL...  and we are in agreement that the Champion / Panther / Viper seat looks perfect on a tracker - a file shot of my daughter's bike from awhile back.
Pat
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 05, 2017, 09:55:13
Thanks! This was actually my first project using a tube bender.  It took me 3 tries to get it perfect.  But with having the DRO on the bender and a magnetic angle finder I can easily repeat it now.

 The champion style seat does look amazing.  I think it looks better than other options especially when the tank has curves to it.  The only frustrating part is there seems to be no availability of a prefeb seat hoop for them.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 06, 2017, 21:02:45
So question for everyone.  For paint I know I want to use something like the honda Imola Orange, and a gun metal gray.  Here is the orange http://quiktouch.com/image/cache/data/Color/Honda_YR536P-500x500.jpg .  Here is the gray http://cdn.eastwood.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/p/5/p50283zp-meteor-gray-metallic_1.jpg .

 Now my question for you guys, should I do the frame orange with gray tank and seat, or the opposite with a gray frame and orange tank and seat?  I do plan on doing something on the side of the tank, like the old yamaha print in gold leaf or similar.  But I am leaning towards orange frame, because almost every tracker style XS has a black or silver frame. 
Title: Re: xs650 Sumotrack
Post by: 1fasgsxr on Sep 07, 2017, 13:19:17
Personally I would do a darker frame. I would want people to see the whole motorcycle not just a bright frame.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 15, 2017, 15:14:12
2 more braces and the frame is basically done.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Sep 30, 2017, 19:40:43
Small update.  Wheels picked up, rear caliper needs maybe 1/32" trimmed off a corner to clear the spokes right at the hub, front everything clears by plenty.   Rear wheel is kz750 hub laced to a 17x4.25 rim, front is the modified cb550 hub laced to a 17x3.5 rim. 

  Seat tube is being modified for a recessed LED integrated strip light. 

  Next big things are finish the headlight/number plate, start wiring, and exhaust.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 13, 2017, 22:19:19
Slight update, been busy at work, and weather has been bad but bends are ordered for the exhaust.  Going to be 1.5" out of the heads, then step up to 1 5/8" go under the engine merge into 1 2" and out the right side.  There will be a bung welded in right after the merge for a wideband O2 sensor.
Title: Re: xs650 Sumotrack
Post by: jerrett on Oct 20, 2017, 09:47:57
Great work so far. Can you post some more pics of how you are modifying the rear hoop to take the led strip? I'm thinking about doing the same thing. Thanks
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 24, 2017, 21:04:15
Yeah, I actually cut a few parts for the tail light at work today.  Could have done it at home, but a waterjet can do in 3 minutes what would take me much longer with an angle grinder.  I'll probably get out there to work on the bike tomorrow and will get some pics then.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 25, 2017, 20:38:46
Ok, to do the recessed LED tail light I did a few things.  1 I measured the light, 2. I figured out the center of the tail and how much height would be added by the sheetmetal.  3. I took this info and marked out where to cut on the hoop, 4. I then cut 3 pieces and turned them into 1 to install in the hole I cut.  Then I welded it in place and started in with a flap disc to smooth it all out.  I still need to cap the ends to stop water from having a way into the tube.
Title: Re: xs650 Sumotrack
Post by: Luugo86 on Oct 25, 2017, 22:27:37
looks good man.. Did you just use an angle grinder to do the cutting? Seems like that would be a pain in the ass to cut lol
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 25, 2017, 22:38:45
On the hoop yes, angle grinder with a cut off wheel and flap disk to clean up.  Not that bad to do, but it helps to mark it out well and cut inside your lines.  Then grind/sand to the line.  Cutting the pieces that went in the slot, I was lazy and used the waterjet at work.
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Oct 25, 2017, 22:56:35
Very nice!
Title: Re: xs650 Sumotrack
Post by: jerrett on Oct 26, 2017, 08:42:34
Thanks Rat_ranger. Love that install. So clean...
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 26, 2017, 09:29:58
No problem.  If you haven't done anything like this before I would recommend getting the cheapest hoop you can find and do a practice run.   It isn't that it is really hard, it is more of how easy it is to mess it up.   But really that can be said of most fabrication.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 29, 2017, 20:40:04
I have tires! Unfortunately I made a rookie mistake and pinched the front tube.  So I have to get a new tube and pull the tire half way off.  I am going to make a tire changer, I figure for the price of even a cheap one I can do better.
Title: Re: xs650 Sumotrack
Post by: Pete12 on Oct 29, 2017, 23:08:21
Wow, looks great with the rubber in place.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Oct 29, 2017, 23:32:19
Thanks! I'm pretty happy with the tire and wheel size.  Front is a 120/70r17 on a 3.5" rim, rear is 150/70r17 on a 4.25" rim.  Tires are shinko 705s.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Nov 04, 2017, 22:57:44
Semi related to the build I got a second engine the other day.  Not much done on the bike as its mostly waiting on funds.
Title: Re: xs650 Sumotrack
Post by: beachcomber on Nov 05, 2017, 10:04:57
Great work to date .. keep pix coming !
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 02, 2017, 18:50:12
So I took advantage of diyautotune having a black friday sale and ordered a microsquirt.  I have a plan to do an in-tank fuel pump and have been working on throttle bodies.  After checking suzuki sv650, hyosung gt650, triumph bonneville, and k1 gsxr600 ITBs, I decided to use the ones from the gsxr as they fit the BS38 carb mounts.  Now, the apacing is pretty far off, but they are very easy to respace. 

 I will be mounting them "upside down"  for easier throttle cable routing.  So the injectors will be on the bottom.  The microsquirt will fit under the seat.  The only thing I have to figure out is where to mount the coils.  I'm going to use LS coils as they are fairly small, have a built in ignitor, and you can find them about everywhere.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 09, 2017, 19:25:20
Slight update, got a new front tube and installed it successfully.  So now both tires hold air.  Other update is I started making the block off plugs for the secondary butterflies that the gsxr used.  So nothing big looking to show change, but there is slow progress.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 15, 2017, 21:33:25
I was busy at lunch today.  Turned some 3" aluminum into stacks that'll let me run 3" ID uni pods.
Title: Re: xs650 Sumotrack
Post by: CrabsAndCylinders on Dec 16, 2017, 01:29:20
Those stacks look beautiful. Are they a turned shape and length?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 16, 2017, 08:30:43
Yep, I ran them in 2 ops on the lathe.  First I did the front radii and ID which has a 3.5* taper from the opening radius down to the throttle body, the second op faced off the back and did the external shape as well as the counterbore that fits over the throttle body.  That is the nice thing about cnc, with a good program and set up you can make parts that are extremely close to being the same.
Title: Re: xs650 Sumotrack
Post by: crazypj on Dec 18, 2017, 12:26:43
If your planning engine mods extra to the 180 re-phase I would fit a second front rotor.
Although I haven't done anything with XS650's for a while, 800-840 conversion with long rods (Honda CR500) is always good for a high torque motor  ;)
I really like the Megasquirt idea, been following Bowling and Grippo for many years (from the time before there was even a kit)
 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 18, 2017, 13:13:57
Engine work will depend on budget.  I'd like to do a long rod 750, but it might just get a rephase.

  Megasquirt isn't too bad to deal with.  I have a ms2 set up on my triumph spitfire running a Toyota 4age with ITBs.  Without that experience I would probably be more apprehensive about going this route.  I figure if I can get the stock engine running in MS, then do a rephase and change settings to adapt it'll be simpler as well as giving a base map for both set ups.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 23, 2017, 19:49:32
Well, it doesn't look like much but the rear seat mount is installed. I'm using 1 of these https://m.ebay.com/itm/Silver-Universal-Push-Button-Billet-Hood-Pin-Lock-Clip-Kits-Auto-Car-Quick-Latch-/182792166421?nav=SEARCH

I think it looks pretty good.  It is made of aluminum, and works well so far.

I also threw the air filters on to see how it looks.
Title: Re: xs650 Sumotrack
Post by: crazypj on Dec 31, 2017, 14:47:21
I like the quick release push pin thing, probably get a few when I have some cash in Paypal  ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Dec 31, 2017, 20:48:34
Yeah, the little push button is pretty cool, and they do have them with different diameters.  I don't think I would trust it as a hood pin, but for a seat, or side panel hold down it'll work as well as a dzus.
Title: Re: xs650 Sumotrack
Post by: hooligan998 on Jan 02, 2018, 01:21:26
Nice build so far.  Love the work.  In.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jan 02, 2018, 20:50:33
Now I just need to mount the number plate.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jan 14, 2018, 18:50:18
Working on a tedious part, the wiring.  To do that I'm using a bunch of CAD( cardboard aided design).  So far I have where fuse boxes, relays, ecu and battery will sit figured out, and have a cardboard template for the pan done.  Waiting on solder and shrink wrap to really run wires. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Feb 11, 2018, 11:21:48
No picture for this update, I spent a decent amount of time making a rotor adapter to line things up on the rear brake.  Then found out the rotor bolt pattern was too big, and the adapter hit the caliper before the axle lined up.  So now waiting on a different rotor to make a new adapter.
Title: Re: xs650 Sumotrack
Post by: crazypj on Feb 11, 2018, 12:35:56
It's never a learning curve building 'custom' bikes, it's a cliff  ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Feb 11, 2018, 12:44:22
Very true, little things you overlook will stop you cold. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Feb 17, 2018, 22:45:29
Well 2 pictures of todays work.  The rotor spacer is complete for the rear, and the exhaust will be ready for ceramic coatimg next week.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Feb 24, 2018, 21:27:34
Rear rotor is mounted, custom throttle cables are made, electronics tray is underway.  And no picture but the header is out for ceramic coating. 

Throttle cables are a mix of motion pro revolver at the handlebars, and ducati st4 I think at the throttle bodies.  The cable ends were turned out of some brass rod I had sitting around and all soldered together using bicycle cable.
Title: Re: xs650 Sumotrack
Post by: crazypj on Feb 24, 2018, 23:30:25
I use a lot of bicycle brake inner cable for throttle cable, same diameter wire plus outer sheath is available in various colours.
I've also used lengths of heat shrink for brake line and clutch cable covers so everything more or less matches  :o

 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Feb 25, 2018, 00:00:11
Nice thing about the bicycle inner is you can get a 10 pack of really long ones on amazon for about $10.  So with modifying the revolver outer with part of a used ducati cable I have under $20 in a custom cable.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 01, 2018, 11:32:10
Made a small but needed part this morning.  Longer sprocket bolts for the kz750 hub.  Looked around and no one seems to make them, but I have to space the sprocket out.  So I pulled some hardened 17-4 stainless out of the scrap bin and got busy.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 01, 2018, 23:34:39
Bolts are good, cut down the original 530 sprocket as a spacer, and now the sprockets are within .01" of perfect alignment.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 03, 2018, 09:41:29
Headers are back from ceramic coating, and clutch slave is done.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 03, 2018, 15:05:00
Plate mount and second tail light mounted.  My reasoning for running 2 tail/ brake lights, the one sunk into the hoop is not marked DOT and I'm iffy on the brightness, the one on the plate mount is DOT marked and gives that much more visibility.  The plus side is if I pull 2 bolts the entire plate mount comes off, cleaning up the tail if I ever take it to a show.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 03, 2018, 16:48:35
You can't have too much taillight.   8)
I followed a Yamaha 'V-Max' with blacked out tail light, looked cool but almost rammed it a few times as I just couldn't see if brake light was on going into corners. Even with  good rear lights, there is still a possibility of some asshole ramming you at  stoplightslights
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 03, 2018, 17:29:36
Yeah, up here people really don't pay attention so I want to be as visible as possible.

I was able to roll it outside and look from more than 3ft away.  I'm pretty happy with the look.  I did lower the rear suspension by 3/4" to get the rake out to 24.8*. It was at right under 24 which seemed a bit steep.
Title: Re: xs650 Sumotrack
Post by: Popeye SXM on Mar 03, 2018, 23:19:10
Looks great
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 03, 2018, 23:58:26
How have you fitted tank? I've got an early YZ tank almost identical to that one  but it's way more 'nose down'.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 04, 2018, 00:02:26
Its a dt tank, I literally just slid it into the original front mounts.  I know with replacing the back half the frame the rear mount is higher than original for the xs.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 14, 2018, 23:13:34
Not picture worthy, but it is down to a bare frame and smoothed out and prepped for powder coating.  I work 4-10s so friday is one of my days off, and the day it will go out to powder.  The plan is to have the frame coated in prismatic's illusion cinnamon.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 16, 2018, 18:24:15
Well the frame is at powder coating.  So I started cleaning up the engine.  A few minutes with eagle one etching mag wheel cleaner doea a whole lot.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 17, 2018, 10:24:29
Well new pistons are on the way.  Some of the gaskets had been seeping so I wanted to replace gaskets and seals.  Got the head off and realized the front cam chain guide had no rubber on it.  Then I got the ID measuring tools out.  Cylinders are .0005 over max standard bore at the smallest and about .005 taper. 
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 17, 2018, 17:58:00
That's a lot of taper. Majority of 650's have had pretty hard lives, I know mine did  ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 17, 2018, 18:56:43
Yeah.  Looks like I'm going to need new rods while I am at it.  There is no copper left on the little ends.  So I guess I should do the rephase now since the crank has to come apart.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 17, 2018, 23:43:20
On the outside of rods?
There never was any copper on the 'inside' of small end
 I've seen them heat blackened several times and also worn oval  but they do seem to be very strong
 I had an XS crank given to me where rod had bent about 60 degrees sideways but kept running long enough for flywheel gear to wear away almost half the piston pin and most of the piston. Unfortunately I never could find out how it happened.
If your doing re-phase it may be worth doing the CR500 rods plus shorter 78mm~82mm pistons. (87mm is max bore size with new liners)
 Cost isn't going to be a heck of a lot different
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 18, 2018, 11:34:32
Well, no matter what the rods are done for.  Probably oval, but enough deep scratches that it would cause problems.

 I want to do a long rod set up, but if I want the bike on the road this summer it's not going to happen.  With 2nd over pistons, new rods, gaskets and seals I'll probably have about $500 in the engine.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 19, 2018, 22:28:28
Tear down 90% done.  Not pictured I had to drill out the drain plug from the lower case.
Title: Re: xs650 Sumotrack
Post by: teazer on Mar 20, 2018, 00:29:49
Yeah.  Looks like I'm going to need new rods while I am at it.  There is no copper left on the little ends.  So I guess I should do the rephase now since the crank has to come apart.

The copper plating was only on surfaces that were not hardened.  Small end eye and big end were plated prior to being machined to size and before they were hardened. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 20, 2018, 10:16:09
Yeah, lots of conflicting info online.  I have seen where a fairly reputable shop says if the plating is worn the rods are done.  Mine have enough scoring that it doesn't matter if they should be plated or not.  The play is visually big enough that I didn't bother to measure, especially once I saw the scoring.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 20, 2018, 13:34:04
No turning back now.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 20, 2018, 21:28:39
Getting the info from 'Chopper Underground'?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 20, 2018, 21:52:09
No, haven't really been on that site.  The different xs forums and a few articles on others is where I got some info.  For hard measurements I have the manual.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 21, 2018, 23:18:01
Waiting on rods now.  The cam is done.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 22, 2018, 23:21:38
The big end pins both have pretty good gouges from the thrust washers.  So it's probably a good thing I split the crank fully. 

 I'm making some parts for a welder at work so I can have him weld the crank for me.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 23, 2018, 22:52:45
No, haven't really been on that site.  The different xs forums and a few articles on others is where I got some info.  For hard measurements I have the manual.
It was posted there first so thought that's where you saw it. It's a much easier mod than cutting and welding cam, wish I'd thought of it 10+ yrs ago when I did my 800.  ;D
I got hold of a copper plumbing fitting (around 3" dia) and cut it up to keep heat and spatter away from centre main bearings when welding pins. Even if your using TIG it may be a good idea?
 Was there any wear from bearings? If it's just the thrust washer area it shows it's been run without oil changes. (dirt gets embedded in edges of bronze thrust washer , high rpm centrifuges washer into pin)
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 23, 2018, 23:41:46
Ah, I don't think chopper underground is even working. 

I've got the crank bearings removed, so not too worried about that.  The left rod bearing had rust on a few rollers.

I did get the cases and cylinders cleaned up today.  Soda blasted, then cleaned in a parts washer, blown out, then washed again 3 times. 
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 24, 2018, 11:25:46
Sounds expensive, bearings were $50.00 each last time I looked.
I rebuild entire crank as it's easier to check everything is running true (and 'adjust' if needed) then weld it up.
I've been using Honda CR500 rods with bronze bush small ends, have 6~8 stock (130mm) rods, too good th throw away but not useful at present (although I may try a modified stroke CB360 crank sometime, bought a spare 360 crank few years ago  ;) )
Modified XV750 pistons give you 800cc (need XV liners in block though)
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 24, 2018, 11:36:43
I ordered the rod kits from mikes xs.  So they come with new pins, bearings, thrust washers.  Crank bearings look good.  I do have a spare crank as well, but it's rods look rough.

  Other than rephase this one will be pretty stock.  2nd over pistons, maybe a hotter cam this winter.  Big thing will be the fuel injection, which reminds me I need to throw the vise back on the mill and drill the fuel rail.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 24, 2018, 11:39:21
Yep, really like the way that's going, fuel injection is going to be a major upgrade when you get mapping right
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 24, 2018, 11:49:43
Tunerstudio makes it pretty easy to get a pretty close tune, and with the wideband it'll adjust the fuel within the parameters you set.  Biggest one to get right is the timing map, so I'm setting it to mimic the stock curve to start.  Then once I have a decent street tune see about a little dyno time.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 24, 2018, 12:21:59
Kinda forgot things have improved dramatically from a few years ago
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 24, 2018, 12:47:37
Megasquirt is simpler than most people think.  But if you change it over to MSextra code it vastly improves the functionality.  Plus tunerstudio is miles ahead of the old tuning software.  The big reason most tuners won't touch it is they remember the MS1 days and the hassle and issues especially when built by an amateur.  But Thins have definitely gotten better.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 26, 2018, 23:00:33
Got my pistons from cruisinimage.  They look good and are withing 1g of each other, so I will see about getting that a little closer before install.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 26, 2018, 23:56:26
That's a good weight match for production parts. Plenty of area's you can remove 1g, probably more difficult not to remove too much ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 27, 2018, 00:05:36
No kidding, I'll probably use an air pencil and just work on removing a bump where a casting seam was on the inside.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 27, 2018, 10:36:34
LOL, yep, 'not enough, hmm, still not enough, little bit more, Oh *^%**!'
 Now do the other one to match  ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 28, 2018, 08:50:27
Even better, measured the pistons and they are within .0001" of each other.
Title: Re: xs650 Sumotrack
Post by: crazypj on Mar 29, 2018, 15:12:11
Things have really improved since CNC as become 'normal' in manufacturing. It hasn't been necessary to buy 4~5 sets of WISECO pistons to match up a 'good' set for at least 10 yrs  ;D
To be that close they must be temperature controlled or something as just turning stuff can change the dimensions as cut progresses (even with flood coolant) Impressive  8)
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 29, 2018, 15:18:49
Yeah, for being cheap pistons they seem pretty good.  I know the machines I run have temp compensation in the controller and do pretty good.  But not quite that good.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 30, 2018, 15:08:00
Got my frame back today.  The color is illusion cinnamon from prismatic.
Title: Re: xs650 Sumotrack
Post by: doc_rot on Mar 30, 2018, 16:09:26
Nothing like fresh powder. What's your plan for the body color?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 30, 2018, 16:25:00
Galaxy grey from house of kolor.  And I want to replicate the decal on the tank, but match the frame color instead of white.  But that'll take someone with more talent than me on painting, so it might not happen for a bit.
Title: Re: xs650 Sumotrack
Post by: doc_rot on Mar 30, 2018, 18:00:23
love that grey, similar to what i painted my kz1000. I think the white and black original decal might look good, plus you could add small white elements elsewhere to really tie it all together. too much of the cinnamon will detract imho, but you do you; its your bike!. Its looking great.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 30, 2018, 18:25:59
Thanks!  I'm not 100% sure on the decal.  It's an idea and if I knew how I would try it in photoshop first.
Title: Re: xs650 Sumotrack
Post by: doc_rot on Mar 30, 2018, 23:38:32
when you get the bike assembled take some straight side shots of it and Id be happy to photo shop some ideas
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Mar 31, 2018, 11:08:45
That would be awesome!  Thank you.  It'll probably be a couple weeks, I have to finish the engine before I really get assembling.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 06, 2018, 21:55:00
Well, the bottom end is together, the valves are cleaned and lapped with new seals.  The cylinders are out getting bored, so I am playing a waiting game on prepping things for assembly.  Can't really get started until the engine is together and in the frame.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 21, 2018, 10:15:35
Well hopefully some pictures today.  Got the cylinders back, checked the ring gap which was perfect out of the box.  Have to degree the cam in and then I can get the motor back in the bike and actually start assembly.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 21, 2018, 23:35:50
Got some assembly done today.  Still a bit to go, only problem so far is the kickstand bolt snapped.
Title: Re: xs650 Sumotrack
Post by: Markie-V on Apr 22, 2018, 06:14:18
That is amazing! Great work and great looking ride. Love the details like the custom made rear led light. Great suspension work in the rear. Looking forward to seeing the end game!
Title: Re: xs650 Sumotrack
Post by: canyoncarver on Apr 23, 2018, 12:31:45
That frame color really pops!
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 24, 2018, 09:26:11
That frame color really pops!
I was really happy with the color just seeing it on the bare frame, but seeing it in the sun as it goes together I'm even happier.
Title: Re: xs650 Sumotrack
Post by: beachcomber on Apr 24, 2018, 10:38:10
That frame is fargin awesome !! Great choice of colour.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Apr 29, 2018, 22:32:54
A slight update, the wiring is going in.  Chassis is wired, all the loose wires are for the EFI.  Once I finish wiring it all the wires will be wrapped in the fancy electrical tape that has no adhesive.
Title: Re: xs650 Sumotrack
Post by: Luugo86 on Apr 29, 2018, 23:27:39
This bike looks like its gonna be a blast to ride
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 06, 2018, 00:19:47
Wiring almost complete.  I had to order 1 terminal, so once I get that I'll wrap the last of the wires.  Squeezed under the seat is a starter solenoid, 2 relays, flasher relay, microsquirt, 2 fuse blocks with 4 fuses each, ignition switch and wideband controller.  There is still enough room for a battery.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 14, 2018, 01:16:27
Ok, the kickstand has been fixed, the wiring is 99% complete, and the tank and seat have been primed.  The fuel sending unit is just waiting on some line to be complete.  Maybe i really will have it running by june.

The fuel pressure regulator is from a ninja 650 in a custom housing.
Title: Re: xs650 Sumotrack
Post by: doc_rot on May 14, 2018, 04:28:11
its looking great man
Title: Re: xs650 Sumotrack
Post by: crazypj on May 14, 2018, 13:09:53
Your truck in background makes bike look tiny  ;D (and I know it isn't )
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 18, 2018, 16:10:35
Lol, it is fairly compact.  But it really is average size for bikes. 

Working on adding a little more color today.  Laying down galaxy grey from HoK on the tank, seat, and fender.  Just color so far, one more coat and then I'll move onto the 2 part clear.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 19, 2018, 14:25:07
I think it needs something on the side of the tank, but I'm pretty happy with the colors.  Still have to sand and buff everything.
Title: Re: xs650 Sumotrack
Post by: doc_rot on May 19, 2018, 17:28:39
snap a pic of it in front of your garage door or hang a sheet behind it and ill do some photo shopping
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 19, 2018, 21:19:13
Here's the best I could do.  Don't have any white sheets and I have too much junk infront of the garage.  I think I prefer the simpler stripe they had in other countries, that's the second pic.  I'm thinking black stripe, with the yamaha in gold leaf.
Title: Re: xs650 Sumotrack
Post by: 3DogNate on May 20, 2018, 19:23:46
Cool.. that'll work
Title: Re: xs650 Sumotrack
Post by: doc_rot on May 21, 2018, 15:40:21
Here you go man, I dig the stripe you picked. IMHO you got a lot of different colors going on and the stripes are an opportunity to unify, so I took a little liberty and tried a couple other color combos. Now that the stripes are drawn its easy to change colors. let me know if you want to try something else.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 21, 2018, 22:12:21
Awesome!  I'm probably going to put black pre-filters to hide the red on the pods.  I'll probably go with the first one, just black stripe and yamaha in gold leaf.  Thank you, it looks awesome.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on May 27, 2018, 20:30:42
Started planning out the stripe on the tank.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 02, 2018, 00:11:29
Paint is about done.  I tried a practice piece for the gold leaf and decided I need to practice more before commiting on the tank. But tomorrow I can mount the fuel pump.
Title: Re: xs650 Sumotrack
Post by: XS750AU on Jun 02, 2018, 05:34:08
It is looking fantastic - well done! ;)
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 02, 2018, 17:32:57
Thanks!  This bike is making up for all the projects I attempted before I had to tools and knowledge to do it right. 

Fuel pump is in its home.  Going to get a 2 pin weatherpack connector for the wires.  With the right crimpers those connectors are great.
Title: Re: xs650 Sumotrack
Post by: 3DogNate on Jun 04, 2018, 23:04:47
yeah.. hell yeah! Keep going. I like how that paint stripe turned out.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 08, 2018, 17:17:48
Well, I learned a lesson today.  Kemso fuel pumps kinda suck.  I had tested it and all was good, but when trying to crank the bike I wasn't getting fuel pressure.  So pulled out the multi-meter and checked that there was voltage getting to it.  I knew the relay was coming on because the coils are run by the same one.  Had voltage, so I pulled the tank and removed the pump.  connected it straight to a battery and nothing.  So now I am waiting on a quantum pump that should be here today.  But In good news I have the timing dialed in at a fixed 10*, meaning I can switch over to the spark table and should be good.  And yes, I checked timing on both cylinders since it is a rephase to make sure I have the oddfire setting right.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 10, 2018, 00:25:44
First start, now it's time to get it on the road and start tuning.
https://youtu.be/nHfOs7GMnno
Title: Re: xs650 Sumotrack
Post by: Aussie Steve on Jun 10, 2018, 02:54:51
First start, now it's time to get it on the road and start tuning.
https://youtu.be/nHfOs7GMnno
Hell yeah!


Sent from my Lenovo A6020a40 using DO THE TON mobile app (http://r.tapatalk.com/byo?rid=89466)

Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 14, 2018, 23:55:05
Ok, so I got a few heat cycles on the engine and retorqued the head.  I also replaced a cam seal while I was at it, one decided it didn't want to do its job.  I'm slowly getting some tuning done, I synced the throttle bodies today, and started fiddling with the fuel and ignition map as quick throttle move would cause a stumble.  i wish there was a better selection of smaller throttle bodies, I really think this engine would be happier with 31-32mm throttles instead of 38mm.
Title: Re: xs650 Sumotrack
Post by: crazypj on Jun 15, 2018, 11:22:31
I doubt the modern 250/300/350 singles/twins are available except as OEM which would make them very expensive? The no idea of throttle bore on MX 250's? May be bit smaller?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 15, 2018, 12:19:44
I think the cbr250/300 is a 40mm.  Plus the singles would take more machine work and thought to link properly.  I know the gpz1100 and the kz750 turbo had 31 or 34mm, but it would take adapters to fit standard injectors.  I might try making a "choke" like the side draft webers use to bring the bore down to 32 or 34mm.  I have the center bodies from the rack I can experiment on. 

Also it takes a good bit more fiddling when there are no base maps available. 
Title: Re: xs650 Sumotrack
Post by: crazypj on Jun 15, 2018, 19:23:08
I was thinking along lines of TU250 Suzuki
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 15, 2018, 20:25:38
It is a good size, but linking a pair doesn't look very easy.  Also with how the injector mounts there probably aren't many higher flowing ones that'll fit.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 17, 2018, 02:46:05
Well I have a headlight and speedometer now.  The number plate will be painted once I'm fully happy with it.  The light staryed as a generic ebay LED projevtor with high/low and angel eye.  As you can tell, I'm not a fan of angel eyes, so the light was modified.  The speedo is an inexpensive 60mm gps speedometer with built in antenna. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 22, 2018, 10:55:51
Can anyone guess what these parts will be?  Made them yesterday getting ready to finish one of the last things the bike needs.
Title: Re: xs650 Sumotrack
Post by: cb250nproject on Jun 24, 2018, 01:25:16
Such a wicked build definitely following


Sent from my iPad using DO THE TON
Title: Re: xs650 Sumotrack
Post by: crazypj on Jun 24, 2018, 12:00:30
No idea what the parts will be? Axle end for pit stand or frame sliders?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 24, 2018, 15:51:42
Rear brake lever pivot.  The shaft goes through the stock pivot hole in the frame, the hex piece has a bronze bushing and will get the pedal attached to it.

 I got busy though because during a test ride I discovered it would not stay in 1st.  Pulled the engine yesterday, opened the bottom end and found a bad shift fork.  Pulled the spare transmission apart and swapped the good shift fork in.  Engine is back in, almost done reconnecting everything. 
Title: Re: xs650 Sumotrack
Post by: crazypj on Jun 24, 2018, 18:33:51
Ah, makes sense. Are you going to do aluminium or stainless?  Sometimes it's pretty amazing you can do stuff when you really want to. I havent been in that much hurry last several years  ;D
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 24, 2018, 19:17:59
Probably stainless, the pivot pin is 15-5, the hex piece is 17-4, and the bushing is aluminum bronze, mostly out of the scrap bin from work.  So I'll probably do some cardboard aided design to figure out the lever shape.

Funny part is this winter I'll be pulling the motor again to put an xs1 cam in.  I want to dyno the bike once I have a decent tune in, then dyno again with the xs1 cam to see the difference.
Title: Re: xs650 Sumotrack
Post by: crazypj on Jun 25, 2018, 16:11:52
I'll be happy to know as well, I've had an XS1 cam sitting around a few years now.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jun 29, 2018, 21:52:47
Well some progress has been made, the replacement shift fork and 4th sliding gear and now it stays in first when you want it to.  The new starter gear #4 and I no longer get the nasty grinding sound with no cranking.

I put about 15 miles on it testing things out close to the house, still has a bit to go on the tune.  Off idle is a bit wonky, that'll take some tweaking to get right.  But it is getting closer to being able to go out further.  The PMA provides plenty of charge, cruises at 14v even with all the load on it.
Title: Re: xs650 Sumotrack
Post by: Popeye SXM on Jul 02, 2018, 21:53:57
Great bike. I came across these on ebay, just a suggestion, I think they are 32mm www.ebay.com/itm/2013-2017-KAWASAKI-NINJA-300-EX300-OEM-MAIN-FUEL-INJECTORS-THROTTLE-BODIES/283018841675?_trkparms=aid%3D444000%26algo%3DSOI.DEFAULT%26ao%3D1%26asc%3D52910%26meid%3Dddd962efb7124a8b80f3b18e5fc7459b%26pid%3D100752%26rk%3D3%26rkt%3D6%26sd%3D253687248166%26itm%3D283018841675&_trksid=p2047675.c100752.m1982. any how good luck with the tunning
Title: Re: xs650 Sumotrack
Post by: JustinLonghorn on Jul 03, 2018, 08:09:15
I can definitely dig it.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 03, 2018, 09:29:19
Great bike. I came across these on ebay, just a suggestion, I think they are 32mm www.ebay.com/itm/2013-2017-KAWASAKI-NINJA-300-EX300-OEM-MAIN-FUEL-INJECTORS-THROTTLE-BODIES/283018841675?_trkparms=aid%3D444000%26algo%3DSOI.DEFAULT%26ao%3D1%26asc%3D52910%26meid%3Dddd962efb7124a8b80f3b18e5fc7459b%26pid%3D100752%26rk%3D3%26rkt%3D6%26sd%3D253687248166%26itm%3D283018841675&_trksid=p2047675.c100752.m1982. any how good luck with the tunning

 Only problem is that you can't respace them.  If I was going to smaller ones I'd probably pony up the cash for a set of gpz1100 throttle bodies since they are each seperate.  If the spacing matches it would be nice and easy though.  I think that's part of the reason the early 2k gsxr600 ones are popular, easy to respace.

 Thanks Justin!
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 06, 2018, 22:09:27
Fuel sending unit version 2 is done.  This will allow better flow, with less points to possibly leak pressure.  Fuel pressure regulator is from a kawasaki ninja 650, the cap of the small chamber was machined for it to fit and be held in with a snap ring.  The cap has an o-ring seal with the body.  The nipple on the side is for the fuel pump to connect, and the wires will be terminated with ring terminals and bolts passing through the delring piece that has 3 orings for a seal with the body. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 08, 2018, 09:08:00
Well the new fuel set up was installed in the tank.  Holds fuel pressure better and higher than the old set up.  Took it for a test ride and once I hit 4400rpm above 42% throttle a cylinder was dropping out on me.  Must have been a sticky injector because I swapped it for a spare and suddenly it is way too rich everywhere. 
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 08, 2018, 22:46:37
Ok, clean injectors in and a very leaned out fuel map finally has it running to redline without dropping a cylinder.  Pulls well all the way to the rev limiter that is set at 7500rpm, I could probably raise that to 8000k since the factory redline is 7500.  But I can finally go on a longer ride and really let autotune do its thing.  It has been an adventure working on the efi with no baseline map to start with.  The good thing is that once I get a nice long datalog I can look at switching to ITB mode.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 13, 2018, 16:48:29
Ok, so it is on the road now.  Handles well, is nice and stable, tracks straight if I let go of the handlebars.  Tuning is coming along, it pulls all the way to redline now, and pulls from just above idle in 5th gear.  It does have a slight hiccup when pulling from low rpm, but more riding with autotune will help get rid of it.  Working on smoothing out the cold start a bit more, and last things left are to mount the horn, and paint the numberplate.
Title: Re: xs650 Sumotrack
Post by: RR100 on Jul 13, 2018, 19:01:16
Beautiful bike. Well done.

 What autotune/I controller are you using? I have a Bazzaz with autotune. Even though the Bazzaz uses an average for the cells (rpm/throttle position) that it hits, the tuning, in my experience, seems quite dependent on riding conditions. I look forward to your experience.

R
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 13, 2018, 19:37:00
I'm using a microsquirt ecu, with tunerstudio on my laptop.  I use the autotune feature of tunerstudio to get it real close, then once cells don't change more than 2-3% in a ride I'll stop autotune and switch it to having the wideband in control.  I can set it to give the wideband 5% and it'll correct itself within 5% of the set map.  I've used this process before tuning a triumph spitfire with a 4age and ITBs before and after the first 300 or so miles of letting autotune do its thing, I switched the ego control on and haven't had to change anything in 3 years and about 10k miles.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 14, 2018, 23:37:49
Well I got the rear brake sorted today, and got the 10 micron fuel filter connected.  The fuel filter does need a mount made for it, I have the material I just need the time. But my buddy stopped by and got a short video coming down the street for me.
https://youtu.be/cetNZ7BQ3g0
Title: Re: xs650 Sumotrack
Post by: crazypj on Jul 15, 2018, 17:39:37
Lot quieter than I expected, sounds good  8)
Title: Re: xs650 Sumotrack
Post by: Pete12 on Jul 15, 2018, 19:32:06
Aside from the motor, how does it ride, does it steer OK?
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 15, 2018, 20:03:48
Thanks! I was worried about it being too loud.

 Yeah, it steers well.  Stable up to 70mph, thats just the fastest I've gone so far, tracks straight when I let go of the bars, leans into corners well without feeling twitchy or heavy.  Overall it feels very neutral handling.  Setting it up I adjusted everything so it has 24.7* of rake just sitting, offset is 30mm and I'm going to leave it.  I had thought about increasing the offset, but it feels good.  Possibly in the future I'll look into a slightly lighter springrate up front as it is a little harsher than I would like, but I'll try the damping adjustment first.
Title: Re: xs650 Sumotrack
Post by: crazypj on Jul 15, 2018, 20:38:23
What 's the weight compared to ther bike forks are off? If it's within 50~80 lbs you should be able to tune it out with lighter fork oil  and compression/rebound damping adjustments. Springs should also be relatively cheap if you need them as 'straight wound' are always used in modern 'cartridge' forks (the progressive damping rates don't work with progressive (multi-rate) springs
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 15, 2018, 21:32:24
The zx6 the forks came off of had a 421 curb weight, a stock xs650 is supposed to be about 480.  I'm sure mine is lighter than stock, but I don't own a scale.  I already backed the preload down, and I'm about to see if adjusting the damping makes a difference.  If that makes a difference but I feel it needs more I'll try lighter fork oil, and then last step will be new aprings.
Title: Re: xs650 Sumotrack
Post by: dakine_surf on Jul 20, 2018, 18:15:09
Damn bud, very inspiring, BOTM once you get it totally sorted.  Honestly, this is one of the best builds on here.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 21, 2018, 14:55:36
Thank you, that is a big compliment.  Hopefully this week I can finish the last few details while I'm in between jobs.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 25, 2018, 23:03:42
Well I'm not calling it done yet, but it's a little closer.  Number plate is painted to match the tank and the headlight ring is painted back pearl.  I feel like it needs a number of something on it.
Title: Re: xs650 Sumotrack
Post by: Popeye SXM on Jul 26, 2018, 01:06:13
For me the head light is too small with out a number or "sponsor's logo". ie too much effort went into the plate and no result. A logo or a number and I think you will have the tracker look nailed. Just my opinion of course, great bike all the same.
Title: Re: xs650 Sumotrack
Post by: crazypj on Jul 27, 2018, 15:28:26
I agree. I'm using 665 or 667 on mine when it's finished (neighbor of the beast  ;D )
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Jul 27, 2018, 16:02:47
Thinking about doing 78 since the bike is a 78.  I just don't want to do an overdone number.
Title: Re: xs650 Sumotrack
Post by: crazypj on Jul 27, 2018, 17:31:00
That works, sounds good to me
Title: Re: xs650 Sumotrack
Post by: trek97 on Jul 29, 2018, 15:05:50
Wow, this is the first time seeing this build.

It looks fantastic.  But the sound of it is out of this world!!!   8)

Im a big fan.
Title: Re: xs650 Sumotrack
Post by: Rat_ranger on Aug 22, 2018, 20:58:42
Thanks everyone! I noticed last night that it's the BOTM, so I went and got some better pictures today.