XS650 Project Black Beauty --- On The Road Yet???

leggers

leggers

Active Member
Hey all! I love this forum and all the advice and comradery you guys have. I've been lurking for quite sometime now, and after doing my craigslist searching I finally found a project, 1982 XS 650 special.

So I'm super pumped because I just picked up my xs 650 basket case off craigslist today and looking to dig in to some work. I got er all home and have been going through the pieces sorting and organizing...

The previous owner had already started disassembling and tore into the engine. I wasn't really looking to go that deep with this project, however I wanted to jump on it for 400 bucks considering all the new parts he had purchased. He chopped the frame and I'll proly be sending that to TC bros for hardtailing.

First thing I noticed was that the case has a chip in it and I'm wondering is this a show stopper?!? Is a new case in order??

enginee.jpg


casea.jpg


framem.jpg
 
Re: New Guy xs 650 build

A bit hard to see but that would be easy to TIG up depending on who you are . There are more than a few experienced XS followers here and second opinions abound throughout the web . I have most of the links .

~kop
 
Re: New Guy xs 650 build

How much mating surface is left in that area between the two cases? You'd hate to have oil pressure forcing oil out the front of your engine.

Given the bike is where it is at, with you looking at having it hard tailed etc., you might want to hunt around for another engine case, or take it to an aluminum welding / machine shop to see if they can build it up for you. You don't want to go through all this effort only to have saved $50 for another engine case and some time, to find it leaks.
 
Re: New Guy xs 650 build

I'm still looking into whether I should have this welded or just get a new case... I will measure to see how much area is actually exposed.

In the meantime I've been working on the wheels, thought I'd share some of my progress:

hub.jpg

The dirty drum on the left, and a good sanding from 150 grit -220 - 320 - 400 final wet sand on the right

hub2n.jpg


Polished with green and white compounds on the wheel.

lacing.jpg

Trying to lace her up. This heritage special is a 48 spoke rim and it was a nightmare, took me 4 attempts just to get it right. But I felt like a badass after finishing it. lol

lacedup.jpg

Laced and polished ready for a fat whitewall tire!! w00t
 
Re: New Guy xs 650 build

feeling like a badass and looks sweet to boot. eyeballin this build
 
Re: New Guy xs 650 build

Tim said:
How much mating surface is left in that area between the two cases? You'd hate to have oil pressure forcing oil out the front of your engine.

Given the bike is where it is at, with you looking at having it hard tailed etc., you might want to hunt around for another engine case, or take it to an aluminum welding / machine shop to see if they can build it up for you. You don't want to go through all this effort only to have saved $50 for another engine case and some time, to find it leaks.
Click to expand...

Thanks for the advice, said fuck it and bought a new case. Tearing into the old one:

img20110628214502.jpg


Did some work to the top end. Painted and sanded fins:

img20110705223044.jpg


img20110705230922.jpg
 
Re: New Guy xs 650 build

Looks promising, dont lose your momentum!!!

As a fellow XS owner I'll be watching this!!
 
Re: New Guy xs 650 build

ProSimex said:
Looks promising, dont lose your momentum!!!

As a fellow XS owner I'll be watching this!!
Click to expand...

Thanks brah! I'll try not to!


More progress:

IMG_20110706_201014.jpg


Transferring the crank and trans gears and seals to the new case was interesting but not as hard as I had anticipated, only took approx. 45min. Oil filter/cover, shift shaft, and shifter were transferred.

IMG_20110707_224026.jpg


Old case on the left.... new on the right. ;D
 
Re: New Guy xs 650 build

Damn bro, talk about doing work ;D Keep it rolling and you'll be riding that thing in no time.
 
Re: New Guy xs 650 build

Got more photos of the tear down? I want to see the other side where the shift shaft fork goes and what's behind the clutch.
I gotta tear into mine soon too.
 
Re: New Guy xs 650 build

xulf13 said:
Got more photos of the tear down? I want to see the other side where the shift shaft fork goes and what's behind the clutch.
I gotta tear into mine soon too.
Click to expand...

All of the lower engine case mechanics have been transferred over to the (good) case. I go into a little more detail on what was done in this video:

http://www.youtube.com/watch?v=TiDsxG9y25U

Exploded view of the shifter shaft assembly:

new+012.jpg


new+010.jpg
 
Re: New Guy xs 650 build

Dude, thanks so much for posting the video and the photos. It totally helped me undertand how the shifting mechanism works and not just look at the shift shaft. I always wanted to visualize that spring which keeps the shaft from pulling away from the case. I spoke about that with Michael Morse (MMM) and he said one of the main reasons these bikes start to pop of gears on their own is because the spring gets worn out or broken with time. Your video showed me exactly what i needed to see.

Thanks again.
 
Re: New Guy xs 650 build

xulf13 said:
Dude, thanks so much for posting the video and the photos. It totally helped me undertand how the shifting mechanism works and not just look at the shift shaft. I always wanted to visualize that spring which keeps the shaft from pulling away from the case. I spoke about that with Michael Morse (MMM) and he said one of the main reasons these bikes start to pop of gears on their own is because the spring gets worn out or broken with time. Your video showed me exactly what i needed to see.

Thanks again.
Click to expand...

Awesome! Glad I could help a brotha out :D
 
Re: New Guy xs 650 build

Assembling the lower half of the engine went well. Have a peek at the video I explain a little more there:


XS 650 Engine Case Build.flv


​

Next step will be to hone the cylinders, clean the pistons, and continue working up the engine.
 
Re: New Guy xs 650 build

Great Job on a super clean video!

I am following this build very closely.
 
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