Topic: XS650 project thread - April 2011 - Getting set for 2nd season :)

[Tim.]

Bits of cam chain glide and other matter all over the place

Milestone achieved last night - tried to start the bike but failed.  Weak battery = no spark from the Boyer (at least I'm hoping this was the culprit).  Will be troubleshooting tonight.  Not everything is completely done yet, but it's close enough to start.

Need to fab up muffler hangers
Waiting on rearset brackets from a friend

I guess that's about it - need to dress up my front brake cable (its stock grey and everything else is black), make sure everything is tight and then once it's running, I can take it down the road!

[Tim.]

Here are the latest pics (April 28) - I take a lot as they help me keep track of what's next.  I spend a lot of time just staring at the bike to figure out what to do next.  Thankfully the list is getting much shorter...

Exhaust is being sorted out - I was going to use frame clamps to hang a bracket from for the mufflers, but I've decided I can get away with a simple flat 1" steel piece running from the top footpeg mounting stud to the muffler hanger, which you can't see on the inside edge of the muffler.  Will hold it up and out in the right position no problem, and the flat stock will be sandwiched between the rearset brackets and frame.  I'll use a large washer on the other footpeg mount to evenly space the rearset bracket off the frame.  Probably 1/8" x 1" wide flat stock which will ultimately be powdercoated black to match the frame and dissapear as much as possible.

The engine covers are now on, along with the clutch mechanism being cleaned, greased and adjusted.  It's heavy, but working properly.  Some engine oil and cable lube will smooth it out a lot.  Those were polished almost 2 years ago, so they need a good buffing, but they're pretty nice.  Need to get a few more long stainless bolts to complete the set.

Need to complete the ignition wires (missing a couple parts at the coil end), toss the kickstart on and rearsets (waiting for my brackets from Joe ) and we'll be nearly there.

[Tim.]

Well, had high hopes of posting a video full of VROOOOOM sounds the other night, but nope.

Snugged up the exhaust (not really on yet, but tight to the engine)
Buttoned up the ignition wires
Put fresh oil in the crankcase
Put the tank on - put fuel in the tank for the first time ever
Opened the petcocks and watched fuel fill the nice filters
Confirmed fuel in the bowls
Turned on the ignition
KICK!
nuthin
KICK KICK KICK pant pant pant KICK KICK KICK (oh yeah, I have a hernia) KICK KICK KICK
nuthin

So I decided to pull the right plug and ground against the engine - turned down the lights and KICK KICK - no visible spark.

Time to trouble shoot the Boyer electronic ignition, which is to say I'll order a set of x-ray glasses from the back of my comic books and stare at the blue box.

[Tim.]

Ok, preliminary trouble shooting suggests I have spark.  Took the plugs out, grounded to the engine and crossed the wires from the Boyer pickup plate and there are nice little blue sparks.  Not the fattest things in the world, but then again, I don't know what they should look like.

So the Boyer blue box is functioning, as well as all the circuitry.  Going to look at different plugs to ensure I'm getting the best possible spark (they're Iridiums or some fancy thing - maybe simpler is better) and I'm getting a can of starting fluid to see if I can get her to at least show signs of combustion.

Once I confirm things are reasonable from a spark perspective, I'll have a more in-depth look at my choke-less Mikuni VM36's that originated on a racing XS650.  I have a nice set of VM34's that just need different jets ready to go with chokes etc., but that means new carb intake boots and air filters.  I'll probably grab the boots tomorrow at Winners Circle and order the air filters.  Chances are this bike will need the more conservative 34mm carbs with chokes.

[Tim.]

Tonight on my way out to our Thursday night 'where are we going' meeting, I picked up some cheater started fluid.  Just got home (2AM) and of course really couldn't possibly wait another 7 hours to try to fire up the bike

Unplugged the H4 headlight to conserve as much power for the coils as possible...

Sprayed a wee bit of magic starter fluid into each open carb...

Ignition on... check...

1 kick - VRRRRRROOOOOOOOOOOM! HIT THE KILL SWITCH IT'S 2 #$%*ING AM!

This is one loud freakin bike.

A ways to go with tuning the carbs before it will run I'm sure, but for the first time in many many years, and certainly for the first time in the 2 years I've been working on this bike it has indeed run.

YAY!  A few days shy of the May 6th 2 year anniversary of my starting on this project (brought it home April 1st 2007 but only really began working on it May 6th when I took it apart).

May 1st 2009 at 2AM the bike roared to life if only for 2 seconds.  Next attempt and real running of the bike will be captured on video.

[hoodellyhoo]

Congrats!!! Gotta love that feeling!

[cben750f0]

WOOOOOOOOOOOOOOOOOT!!!!   congrats M8!!!!!



NOW...video video video!!!!


well done nothing like your hard work commin to life... proud moment..

peace

[Tim.]

I went at it again this afternoon, and got it to run again for a few seconds.  Even sounded a bit like an idle at one point

It is only running with the starter fluid though.  Need to sort my carbs.  I'm probably going to shelve the VM36's with no chokes and bolt on the stand-by VM34's I picked up a while back.  They have chokes and should be a little tamer for the street.  Just need to swap out the needles and a jet or two.

But of course in the meantime I'll fiddle with the 36's this weekend and see what happens.  I'll make sure I get a video too.

[Tim.]

Video!  Actually sounds like it would keep running with some adjusting, but it is popping a bit back through the carbs.  Make sure you hit the little 4 arrow expand button on the video toolbar to go full-screen

Not a valid vimeo URL

[Dougy Dougy Dune Buggy]

Nuthin like the sound when she will fire and you can blip the throttle..cONGRATS TinTin!!
i had one of those same moments a month ago with my CL90..you know what's funny, when i had my XS650 i got more thumbs up than when i rode a harley! Thanks for the Update
Doug

[crazypj]

I just hope you haven't done any damage using starting ether, it has an octane rating of about 3.
I'll have to listen to it again on desktop but it sounded like it was knocking its nuts off on laptop 'speakers'
 Is there any fuel in carbs?
If so, it was running long enough to have picked up.
 You need to get back on 650 garage and go through the carb section.
 http://xs650temp.proboards.com/index.cgi?

 PJ
 

[Tim.]

Oh yeah - the bowls are full of fuel and the petcocks were open.  It's getting fuel for sure.  The short sprays of ether were all it got of that stuff.  I'm pretty sure it's ok.  Won't be doing it again soon - going to sort out the carbs and see if I can get it started on its own.

[Tim.]

Getting close now!

Got all the jets etc. I needed from Winners Circle (local Mikuni dealer) and did a rough clean up and install of the VM34's.  Chokes on, kick 2 times and VROOOOM!  Running!  NO STARTER FLUID

Carbs are out of synch, dirty and not tuned at all, but it runs without starting fluid!  Took the carbs off for a proper cleaning and bench sync, and am working on proper carb intakes with barbs on them for vacuum balancing.

While that's being done I'll do the final bolting up of the exhaust, some polishing etc. and hopefully in a couple more weeks take it out for a spin!

[mrbreeze]

ROCK

[tsflstb]

This is one of my favorite "other bike" builds.

Looked like you had some momentum going...hopefully you're spending all your time riding it now.

Any updates?

[Terry in Australia]

Got an update Tinny? You must have ridden the wheels off that thing by now? Looks fantastic!

[Sam Green Racing]

Cool Tim.

Sam.

[Tim.]

Some other nonsense got in the way of the bike work.  House reno work, work work, then I dumped the BMW, managing around a hernia (surgery this coming week) and am out of town for a few weeks.

So no, I'm not riding the wheels off it sadly, but will be soon I hope.

[Tim.]

Update - been a long time.  Bike is nearing completion.

Did a couple hours this weekend in the garage - bolted on rearsets etc.  Just a few more bolts and it's all together.  Need to reshape the kickstarter to clear the rearsets and play with the angle of the rearset levers, exhaust etc.

[Tnutz]

gorgeous.

god i miss mine....i chopped a standard...complete...not knowing...i would have rather done a mild cafe out of it.  sold it as i can't deal with that twin in a hardtail frame...  easiest motor to work on. easier than my honda.

[BeSeeingYou]

The bike looks really great.  Sounds like you have your carb issue fixed.  These are cold blooded bikes and in 30 years I could count the number of times I started mine cold without the choke on one hand.  The electronic ignition will help.  My 75 project starts without the choke but it runs very rich and once properly adjusted it will stop doing this I have no doubt.

[Tnutz]

mine was a 2 kicker no matter what....choke, kick, kick again and ignition.

[Tim.]

This is what she looks like from the side.  Looking forward to spring!

[Tnutz]

god i really want another one.  looks sharp.

[Terry in Australia]

This is what she looks like from the side.  Looking forward to spring!

Looks great Tinny, but what's up with those pipes mate? They look too low, and it kind of spoils the professional look of the rest of the bike a bit?

The Italians got it right many years ago, here's a pic of my 1972 Laverda SF1 750, the "Conti" pipes aren't swept up real high like some bikes you see, just a nice subtle up turn at the rear. Can you "tweak" your headers slightly mate? Just my opinion of course, I've been waiting for you to finish that beauty with bated breath since you started!