My XS650 build

No pics but I started the wiring today. I am using the stock wiring diagram and Tims to come up with my own. I have a buddy helping me, he also hooked me up with all my wiring supplies. I have pretty much the charging/ignition wired up and will do the lights later.

I am also getting a bunch of randoms put on. I took it to the shop at my school to take advantage of some otherwise wasted lab time. I will try to take some pics next week when I am there.
 
So my stock master cylinder is big, bulky and ugly. I am looking on mikesxs and he has some more lowprofile ones. they are a 16mm bore and then he has an older style round reservoir type, that i really like better but it has a 22mm bore. What will be the effect of the bigger bore?
 
I'm surprised nobody has answered this. And while I can't personally answer it either, just wanted to give the thread a little bump.

I think I read before to use the same size bore, but don't have any explanation for it.
 
Thanks BigR.

I also posted it in the brakes section and got some help from swagger on the matter. He said I could go up to a 17 or 18 but going up to a 22 would require gorilla hands!
 
So, I am trying to decide some things;

First, I am trying to figure out what to do for a battery/electrics box. I have an ammo can but it is not what I am feeling for this bike. I have thought about getting an old oil tank to put under the seat but I would need to find one that i like and would not mind cutting up to modify it for my needs.

Any ideas would be greatly appreciated. I am not sold on a style yet, just not feeling the ammo can.

Second, rear turn signals. I do not even want them but have to by law. I have thought about getting some flush mounted ones to slide in on the sides of the rear fender to try to blend them in. Like this: http://www.motorcyclecloseouts.com/dir/large_img.php?id=24816
My other thought is to do some old style bullet lights also off the sides of the fender. like this: http://www.latus-harley-davidson.com/prodimages/69063_03_L_1bb0e.jpg and this http://www.hoohoohoblin.com/RoyalEnfieldPictures/IMG_2069.jpg

Please share some thoughts!
 
While I like the idea of the surface mounted signals, I don't believe they are as effective as normal signals. Just for safety's sake.

But between the 3 links, I'd go with the Harley ones!

And are you going with the original battery? Just thinking an ammo can is pretty big.
 
What are you planning to do for a license plate? You might be able to do one of those all-in-one LED tail/brake/turn setups where it looks like a single oval light but half can blink at a time for signal. Alternately, is it possible to put a side mount on each side and wire them so that they can blink individually as signals?
 
This is what I am running for my tail light (only without the Plymoth): http://www.allpar.com/cotm/photos/1932/tail-light.jpg

It will be side mounted with the license plate under it. I really like the light and want to use it, it will get an Led bulb but I do not think I can get a bulb that will blink for turn signals also.

I am not using the stock battery, it is a 12V sealed lead acid battery, it is a little smaller than stock but pretty close. The ammo can is a little big but I do have a fairly big Ignition box and rectifier. I do not want to use the ammo can, I am looking for other ideas. The ammo can is just something that I have.

Thanks for the input.
 
Well I'm partial to the electrical boxes on the gravel-crew bikes.

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I'm not sure how that will work with your very low hard-tail, but it might be worth a go. You've clearly got welding skills so you could fab up a mount on the frame and bend some sheet metal or build a fiberglass cover for it. I'm planning to do something similar in glass, but I haven't changed my frame geometry so I have a lot more space to work with.
 
I have been thinking something along those lines. It would give it a more traditional look, like an oil tank, although I can foresee some flack because it is not a v-twin and did not have an oil tank but whatever. I like the look and will have to toy around with something. Thanks
 
They make nice "drum" style oil tanks that arent rel big. They have a battery box integrated into them, and ive seen guys cut them open and make an access panel so you can put all you elec. inside instead of oil.
 
I think I am going to go with something like this: http://cgi.ebay.com/ebaymotors/Vintage-Horseshoe-Oil-Tank-Triumph-BSA-Harley-Chopper_W0QQitemZ320515492627QQcmdZViewItemQQptZMotorcycles_Parts_Accessories?hash=item4aa0364b13#ht_518wt_939

I might modify it a little to match the lines of my frame, and of course to house my electrics.

If I was going to try and start mybike what is a good way to have an alternate fuel tank thing? I was thinking like a gatorae bottle attachen to some fuel lines but am trying to find a valve or something to control fuel flow a little.

What have you guys done?

Thanks for the input guys
 
That's pretty cool, but it looks like it's intended to mount on a wide backbone downtube. Where are you planning to put it?

This is definitely a better look than the ammo can.
 
I AM going to mount it under my seat, I will have to modify the mounting system for sure, also I want to enclose the battery in there also since it will beunder an open sprung solo seat.

I like that style way better than the ammocan also thanks!
 
So I have been working on my taillight, I have some pics and will finish it tomorrow if all goes well. Then I will post what I did.

Also I went to my local skate shop and asked around for a warped or damaged skate deck and ended up getting a deck that has minimal wear on it but has one end broke off, the rest of the board is in pretty good shape. The best thing about it is the price... FREE!! I will do some shaping of it tomorrow also and post some picks. I will have to figure out a hinge system and then get some springs for it but shaping it will come first.

Look for an update tomorrow with pics, hopefully there will be one.
 
So, I did get the Taillight done. But I cannot get connected to photobucket right now to post some pics. I will give a description now and post the pics later. I had a cool old taillight that I got for FREE at an old salvage place and I like it a lot. The issue is the wiring to the light, it had none. So instead of trying to rewire it, which I would not know where to start, I cut the back off and trimmed my original taillight back down to match and welded them together. The welds are a little rough, it was a buddy's 110 harbour freight that is always hot the trigger only controls wire feed. It turned out alright but I think after I grind it down more I might go over it with some JB WELD, just to fill in a couple pot holes and make it all smooth and uniform.

I also started shaping the skate deck and will try to finish the shaping this week, all I had in shop at school was a chop saw so I will finish it later.

Like I said I will post pics later adn hopefully it will help you visualize what is going on.
 
here are the pics

Taillight I want
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Original taillight
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The surgery
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So there it is. I know that is some of the ugliest welding ever, I am not a fan of the always hot mig welder, it is like stick welding with a gun to shot out the wire. It cleaned up pretty good though, I still need to finish cleaning it up but it is getting there.

Here is a shirt my wife found at an old navy sale for my 15 month old.
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I will post pics of the seat when I get the shape all cut out.

Thanks for viewing!
 
Here is a pic of the shape of the seat I have made.
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Also I was toying around with the idea of using the rear shock off of my old GT LTS-1 mountain bike. The prob is I can not get it off the top mounting plate is mounted in the frame rails and the frame rail is one piece right there. I can not figure out how they got it in there or how to get it out.
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any ideas would be good. I will not cut up the bike though so you can bypass that one. also if you think this would be a good idea or not let me know. I would mount it similar to how it is one the mountain bike but I was thinking of doing it upside down so I could mount it sticking down through the frame and not up towards the seat. I would also fab a mounting plate that would bolt up to the truck mounting holes already in the seat.
 
For that shock, you could PM Rocan - if he doesn't know how to get it off I'd be amazed.

Hell, he could probably get you a new one for dirt cheap as well.
 
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