XS650 Rusty Redemption

jetmechmarty

Been Around the Block
I've had a POS (found in junkyard) '79 Special II for a very long time and I have a pretty good idea of what I want to do with it, at least in my head. I picked up another Heritage Special recently. It is disassembled and the collection of parts seems to be lacking the corrosion I'd expect to find. I've already decided I don't want another Heritage (I've had one since it was new.) and mine will enjoy some of these parts.
I'm putting together a mashup. I'm going to mix the '79 with the '83 engine, ignition, wiring, everything. I'll just maintain most of the Special II appearance. The frame I picked up has some Sawsall damage. I won't know what's missing until I do the reassembly.
My '79 engine is locked up solid. The new one is '81 and looks like it's in good condition.

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jetmechmarty

Been Around the Block
Well, this is fun! I mounted an SK battery box in a 2F frame. Then the plastic SK air boxes. Finally, the 2F metal side covers. It looks like this is going to work (maybe). I think I would prefer to run the BS34 carburetors as that would simplify this whole process.
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It’s all going to fit! ‘79 frame, ‘83 battery box, plastic air boxes, ‘79 Sp2 steel side covers and BS34 carburetors.
So, it’s going to be ‘79 frame and wheels, ‘81 engine, and 1983 electrical. I think it’s almost time to dismantle it and start making a bike.

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For reference, this is a '79 650 Special II
 

pidjones

Over 1,000 Posts
Looks like a good plan, but I'd go with modern tire design if you really plan to ride it.
 

jetmechmarty

Been Around the Block
Looks like a good plan, but I'd go with modern tire design if you really plan to ride it.
Nothing is set in stone, yet.

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I chose this '83 tank. It's straight.

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I spun it in the clothes dryer for a couple of hours with 2 lbs of this rust busting media I got at Harbor Freight.

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I finished the tank with phosphoric acid and installed a Caswell epoxy liner.

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jetmechmarty

Been Around the Block
The tank and body side panels have gone off for paint, because I had the opportunity to get it done. The side panels will be black with OE "Special II" decals.
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I chose Toyota Calvary Blue for the tank.

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JB Weld fix.
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jetmechmarty

Been Around the Block
I got a deal I couldn't pass up on these 1.75" stainless pipes.
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They're too big for putzing around Mississippi roads, but there's a fix for that.
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It's a very nice fit right up against the exhaust port.
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These will go into the back end of the pipe. I got these from 650 Central. They are 1 3/8” torque peak optimizers. They go into the exit end of those big pipes I bought. Combined with my BS34 carburetors, they should maximize my bottom end grunt. He has them in various sizes.
 

Rider52

Over 1,000 Posts
I ran his power cones on a set of TT pipes several years ago. I thought they worked very well.
 

jetmechmarty

Been Around the Block
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That was two cups of the phosphoric acid product in that five gallon bucket mixed with water. Where there's rust, it left a hard iron phosphate behind. There was no flash rust. I painted the underside of the fender with chrome color Rustoleum. Once adorned with a taillight, license plate and seat, that fender will probably suit me just fine.
 

porcelanowy

New Member
Hello
I love almost all XS650 projects.
My second ;) favourite vintage yamaha :)
Stainless pipes look good. Trying to find something like this to my SR250 but no manufacturer has pipes specific for that model.
 

jetmechmarty

Been Around the Block
Hello
I love almost all XS650 projects.
My second ;) favourite vintage yamaha :)
Stainless pipes look good. Trying to find something like this to my SR250 but no manufacturer has pipes specific for that model.
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I'm an XS650 geek myself. I've been caring for this one since new. Last weekend, I rode it 600 miles to Barber and back. It's coming up on 61,000 miles. I did the top end last winter.
 

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