Topic: XS650 Gentleman's Express

[Scott S]

 Several years ago, we hauled home a parts bike...and another bike...and another bike. At the time, I had built several custom XS's; cafe' racer, Brat bike, etc. I thought I wanted a stock bike, so I combined the parts of three bikes and built a '75/'78 Combo bike.

 The build thread is here:
http://www.xs650.com/forum/showthread.php?t=620&highlight=75%2F78+combo+bike

 This was probably the longest build I've ever done. I've built VW's faster than this bike! The tank and side covers sat in "paint jail" for a year. The project just dragged on and on...
  I got into CB500/550's for a while and kept building and riding.
 Then , when it was done, there was a top-end noise. The bike ran great, but had a loud noise that just isn't right. The last time I rode it, it was exhibiting an unwillingness to rev. I rode her home, drained the tank and float bowls and took the tag/insurance off her. That's the way she's sat for about a year.

 I finally decided it's time to press onward. Went out yesterday and rigged up a gas source, kicked her over and checked for oil on the top end. She's definitely oiling up there, so I'm stumped as to what the problem is. I guess it's going to take an autopsy.

 This is how she looked when I started:


 And this is how she looks today:


 The engine is ready to pull as soon as I get an extra set of hands. The oil around the head and barrels is from checking for oiling. There were no leaks previously.

[Scott S]

 I realized that I'm not really a stock guy. The bike isn't really a 1975 model and never will be. There are minor improvents that I can make that will help the look, comfort and performance.

 The plan:
 - Better rear shocks
 - Brembo caliper and master cylinder upgrade
 - Euro handlebars
 - Smaller turn signals
 - A comfier seat
 - Commando pipes
 - Better gauges

 ...and more.

[Scott S]

 I picked up a set of Euro bars from a forum member on XS650.com . They already have internal wiring and the correct controls for this bike. I'll probably detail the controls a little bit.



 I've collected the parts for the Brembo caliper upgrade. I already have braided stainless steel lines. The rear already has EBC pads and works great.

[Scott S]

The front forks have already been rebuilt. I added a spacer and a little extra oil to firm them up. Improved handling immensly.




 I have plans for the rear shocks. Stay tuned....

[BeSeeingYou]

If the mufflers are for sale I would be interested.

[Scott S]

 They may be......let get the bike finished first. Haven't decided yet. They're not perfect, but in very nic shape. I'm sure you know how hard they are to come by.

[Stev-o]

Always liked these Yammies....subscribed.

[CycleRanger]

Neat!  I've got a 2 owner '76 that's next up for a refresh after I finish the CJ360.
I'll be interested to see how yours turns out.

[BeSeeingYou]

They may be......let get the bike finished first. Haven't decided yet. They're not perfect, but in very nic shape. I'm sure you know how hard they are to come by.

Just keep me in mind....any other parts you don't use also.  I have a pair for my 75 but one has a nice dent in it and though they are serviceable they aren't the best.

[chung]

I have a 1982 XS650 Special II. Are the Frames different from the XS1 thru the 'Special II? The Steering Head seems a little high? I've wanted one of these since they first came out. Damned good noise, even through the stock Mufflers. They called it the best British Twin that the Japanese ever built ;-) I'll have to do a little homework and I will check out the XS650 Site for more details.
I'm getting a battery this week and plan to ride it for the first time. I fired it several times over the years but have yet to turn a wheel at the helm. Keep me posted on yours please. Shoot me an email and we can swap some Yamaha stories. I have several 2-Stroke Twins too. 
Happy Trails,
Chung

[Scott S]

 Yes, the frames are different. Mostly in the seat area. Yamah, like everyone else around that time, was going for the chopper or cruiser look. I prefer the early bikes myself.

[BeSeeingYou]

I have a 1982 XS650 Special II. Are the Frames different from the XS1 thru the 'Special II? The Steering Head seems a little high? I've wanted one of these since they first came out. Damned good noise, even through the stock Mufflers. They called it the best British Twin that the Japanese ever built ;-) I'll have to do a little homework and I will check out the XS650 Site for more details.
I'm getting a battery this week and plan to ride it for the first time. I fired it several times over the years but have yet to turn a wheel at the helm. Keep me posted on yours please. Shoot me an email and we can swap some Yamaha stories. I have several 2-Stroke Twins too. 
Happy Trails,
Chung

1970-73 frames are the same.  These bikes probably have more value for the collector but the handling is a bit dicey at speed.  Frame was improved in 1974 and with minor differences stayed the same till the end.  For a few years after 74 the passenger footpegs were mounted to a loop on the frame and somewhere along the line that changed to a curved arm.  Some differences in the seat mounting area came around 1980-1.  Stiffer forks came in 77 (34mm vs 35mm).  A vast majority of parts can be swapped in the 74 and newer bikes.

[Scott S]

 Picked up some goody's at Barber. There are great deals to be had in the swap meet!



 Nifty, NOS fuel gauge gas cap. Not 100% sure if I'll use this or not.




 Turn signals. Got these in a package deal with some 400F footpegs for one of my CB's (factory parts that can be used for "rear sets" on the CB500/550s)>

[Scott S]

 I'm planning on swapping in a '72 "long rod" 256 engine we have. IT has a hotter cam from the factory that's supposedly worth 3HP over the later engines. I'll tear into the '78 engine this Winter.

 Here's the seat I plan on running. It was on a parts bike I bought. Very nice leather, padding etc. Super comfy and still looks OK, IMO.

[Scott S]

Spent some time last night taping up the controls on the Euro bars. Covered up all the lettering for the kill switch, light switches, etc., and gave them a coat of semi-gloss black.





 These are the grips I prefer. Randakks sells them as his "Super Grips" or something like that, but they're really just ProGrip 714's. Great look and feel awesome.

[Scott S]

 Installed the grips today and reviewed my wiring in the headlight bucket (remember....this is a '78 frame/engine/wiring harness with '75 controls) and was all set to install the new bars.
 Removed the old bars and asked my girlfriend to assist me while I installed the Euros. Turned my back to get the Allen wrench and heard a CLANG!

 The bars slipped off the counter and landed RIGHT ON THE KILL SWITCH!! AAAARRGGHH!!!!

 Not only did it bust up the switch, it broke the contact plate inside. Luckily, I have a RH control that I saved from a '74 parts bike. It's really rough inside, but the kill switch and contact plate are nice.
 Question: If I melt the solder on the back of the contact plate, what happens to the little brass (copper?) contacts? Will they stay on the plate or will they fall out?
 Should I just cut/splice the wires instead?



 Seriously....I was literally two minutes from being done with installing the bars! DOH!

[Scott S]

 Luckily, my girlfriend has a side job assembling electronics. She has steady hands and lots of experience soldering.
 We were able to repair the RH control kill switch. Pictured are some of the tiny springs, clips and ball bearings that are the workings behind your kill switch. Not shown are two teeny-tiny C-clips. I've rebuilt several Honda controls. It REALLY helps to have three hands and a lot of patience when doing this sort of work.

[Scott S]

 Some before and afters, comparing the stock vs. Euro bars. I still have to do the wiring inside the headlight bucket. I'll probably get to that this weekend.

[Scott S]

 Also got the new shocks installed. My Dad recently upgraded to Progressives and I got these Monza shocks as a hand-me-down. Nice shocks with dual progressive springs. The original shocks were chosen for looks (to make the bike look like a '75). These HAVE to perform better than the worn out stockers.

[CycleRanger]

I like those bars, those shocks, and the nifty gas cap! Good score!

[Scott S]

Rear turn signals mounted. Only now did I realize that I mounted the front signals "upside down", with the screws showing. I'll have to go back and fix that.
 A To anyone running these signals: Did you have to change the stock flasher?

[Scott S]

 And got the engine pulled. After I got it on the stand, I was able to use my impact wrench and get the rear drain plug loose. I've never been able to remove it before.

 We'll tear into this engine and see what's causing the noise. All of the polished bits and the Pamco will be swapped over to the '72 engine.

[Killer Canary]

Those turn signals like to fall apart inside. I had to finally fix 'em with wire clamps.

[Scott S]

 One other little thing I did that will be virtually invisible to everyone but me, I swapped out the lockset for one from an old parts bike. Now the ignition, seat latch and gas cap are all keyed alike.

[Scott S]

 Did the "broken kickstarter post" repair.