XS650 Cafe - Build #4

ncologerojr

Coast to Coast
DTT BOTM WINNER
Now that the cb750 has shipped off to its future home in Australia it is time to start on the next build.



I found this clean running/driving '79 xs650 on craigslist. It has 9k miles and is bone stock except for the sweet seat. I also picked up a set of '05 gsxr 600/750 forks.



 
First thing I wanted to sort out are the wheels. I always prefer spoke wheels, and I want to run wide tires. I got on craigslist to see if there was anything local, and I found these older Harley wheels right in my town. They are 18", wide and were $30 each. So, I'm going to run Harley wheels.



The Harley wheels originally used a 3/4" axel, but the gsxr uses a 25mm axel. Unfortunately, I can not find ball bearings to adapt the Harley hub to the gsxr axel. I could run tapered bearings, but I don't want to deal with the pre-load. So I'll use my lathe to bore 1mm out of the hub to fit easily found 47x25mm sealed bearings.



 
Sorry for the lack of updates. I would love to get this hub bored out, but I need the bearings first to get some measurements. Unfortunately the usps is not helping...

 
trippmann said:
are you a fellow jersey rider?! im in centeral near belmar.

No, sorry. I'm in the Hudson Valley area of New York. I would think that jersey has a lot of dtt members tho...
 
Hard to tell from the pictures, but does the new fork wheel combination lower the front?
Nice bike, I belive the early XS 650s had spoke wheels, might save a lot of trouble with the rear.
Love that bike, great find.
 
rundown said:
Hard to tell from the pictures, but does the new fork wheel combination lower the front?
Nice bike, I belive the early XS 650s had spoke wheels, might save a lot of trouble with the rear.
Love that bike, great find.

Thanks.

The fork/wheel combo should lower the front a bit. Once I have the suspension and wheels mocked up I'll make adjustments for ride height, rake and trail.

The earlier xs's did have spoke wheels, but I was swapping wheels either way so the mags weren't a real concern for me. I am not very good at taking the easy route...
 
Again, sorry for the lack of updates. But, I have been keeping busy in the shop.

I first tore the bike down some more to take some measurements. I ordered some tubing to work on some frame modifications. I plan on re-remaking the rear subframe. I also really don't like the look of the solid area buy the swingarm/peg mounts, so I think I might cut the frame below the engine and re-make that area as well.



I've also decided on making a new swingarm to accommodate a wider rear tire. The stock swingarm's straight taper is too narrow towards the front. It would be easier to stretch the swingarm, but I don't want to extend the wheelbase. Here is a quick design I started working on. Some of the dimensions are off. I'll be using 1x2" .120 wall square tube for the arms. By bending the arms I can keep the swingarm the stock width at the axle, and gain clearance up front.



I've also spent some time improving my workshop a bit. I finally got around to making a good fab table with a 1/2" steel plate top.



That's it for now, I should have more up soon...
 
Got some supplies in for the subframe, frame, swingarm, wheel spacers etc.

e70774019543db593296a2b82ef3f583.jpg


I also got started adapting the front hub to the gsxr axle. It's all set to go, I just need to make the wheel spacers. But, I can't make the spacers until the bearings are in, and I don't want to put the bearings in until the hub is painted/powder coated...

c420db9f671de7fac3ef6ba35f9cf353.jpg
 
I managed to shave some weight off the xs....



The xs used 1 1/8" .083 wall tubing for the dowm tubes, and 7/8' .083 for the subframe. I'm going to use 1" .120 wall for everything, so I turned down some quick frame slugs to match.

 
I found some time to get in the shop today. I step bored the frame slugs to improve welding, and save a few ounces. I also got started on a frame jig to keep everything nice and straight.



 
I found a little time to get into the garage today. I managed to get the frame jig just about finished, and I turned down an aluminum cone for mounting the neck tube to the jig.



 
I know you're building a custom swing arm, but what are your plans for the subframe? Don't recall if you mentioned that or not previously.
 
treitz said:
I know you're building a custom swing arm, but what are your plans for the subframe? Don't recall if you mentioned that or not previously.

The subframe design will be pretty simple. I'm planning on going mono-shock so it will no longer have the stress from the shocks, and will only have to support the rider weight.
 
Ah cool. Didn't realize you were going mono-shock. I'm going mono-shock on my XS850 cafe. Fun stuff!
 
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