Yamaha XS 650

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Yamaha XS 650

Post  desautdw on Sun 27 Nov - 1:33

After selling the KZ1000, I purchased this rough 1977 XS 650. Debating either a cafe or restoration to stock. It runs, but is stiff to push, the electricals are shot and the carbs leak. Time to tear it down and see what it needs. I have already ordered new grips, clutch pivot, wiring harness, manual and carb rebuild kits. Let the fun begin!

[img][/img][img][/img]
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Re: Yamaha XS 650

Post  Toecutter on Mon 28 Nov - 9:04

cool man, i wish you much fun with this icon :)

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Re: Yamaha XS 650

Post  Crazy Cavan on Wed 30 Nov - 14:20

nice project!
a xs650 got lot of potential for every customizeble way but i prefere a caff racer Cool

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Re: Yamaha XS 650

Post  Kenneth on Fri 2 Dec - 20:03

Nice project indeed!

I'm really crazy about the XS 650. If I run into one I will buy one too.

Lot's of fun with this one! Keep us updated.

Kenneth
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XS 650 Progress

Post  desautdw on Wed 11 Jan - 21:48

Cleaned and painted seat pan ready for next step.

[img][/img]
[img][/img]
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New parts for Christmas

Post  desautdw on Wed 11 Jan - 21:50

Some of the parts so far including: clutch lever base, grips, manual, carb kits and new wiring harness.

[img][/img]
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Seat Work

Post  desautdw on Wed 11 Jan - 21:55

Previous owner tried to make it a "special" with humped seat (ugly). So I am cutting and adding foam prior to new cover.[img][/img]

Fuel Petcocks were very dirty inside and out, so they have been cleaned and rebuild kits on order.

[img][/img]
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Re: Yamaha XS 650

Post  Toecutter on Fri 13 Jan - 21:08

Yes indeed , its those little things...that makes a bike run as it should. Very Happy

btw, i see your drinking Bud Light , ! that is not the way of the caferacer !

just havin' a laugh,

cheers man and succes with your 650!

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XS Progress

Post  desautdw on Mon 30 Jan - 6:47

I drink them all! Too cold for much work here right now, but I am starting to remove bits and pieces and see what needs rebuilding, repairing or replacing. Starting to think "cafe" instead of restoration, but both are good.
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Status Update

Post  desautdw on Tue 3 Apr - 21:48

As the weather gets warmer, more gets done. Gas tank stripped down to paint and single air filters I have had for a while look like a good fit. But I found lots of metal flakes in the front oil filter (near oil pump) which means I have either gear box damage, engine damage or both.

[img][/img]



[img][/img]

[img][/img]

[img][/img]
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Progress is being made!

Post  desautdw on Sun 22 Apr - 22:30

Engine is cleaned up some and parts coming off:
[img][/img]

New seat cover is ready to put on:

[img][/img]

Tank down to the basics, ready for paint:

[[img][/img]
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Progress?

Post  desautdw on Tue 8 May - 21:35

Carbs cleaned and kits installed.

[img][/img]

Sump plate cleaned, but the sump filter was falling apart, may have been source of metal particles in sump.
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Re: Yamaha XS 650

Post  Toecutter on Wed 9 May - 20:58

Hell , metal particles when you drained the oil , thats no good , did you ever start the engine ? Just read the first post , it ran, but thats no guarantee the engine is ok.

Hell again... look everything closely , im far from an expert but as you know things can get ungly, read : Crunchy study


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Progress

Post  desautdw on Thu 10 May - 2:48

Less particles in sump than expected, we shall see. Another $200 in parts on its way!
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Re: Yamaha XS 650

Post  Toecutter on Mon 14 May - 20:33

btw , carbs are looking nice,

succes m8te :)

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Re: Yamaha XS 650

Post  GS850 on Sat 30 Jun - 11:55

watch out with those aftermarket petcock rebuild sets, worked for shit on my suzuki, better off buying a whole new one! for about a 100$ you're good to go for another 40 years...
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Petcock rebuild

Post  desautdw on Sat 30 Jun - 18:24

Well, they have been out of stock for months now, so maybe you are right. Now struggling with wiring as the previous owner had done some strange work there and having fits trying to find out what goes where.
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Re: Yamaha XS 650

Post  GS850 on Sat 30 Jun - 20:10

http://www.google.com/search?q=xs+650+wiring+diagram&hl=nl&prmd=imvnsfd&tbm=isch&tbo=u&source=univ&sa=X&ei=kjLvT9GUCYGR0AWYxP3_DQ&ved=0CFYQsAQ&biw=1440&bih=805

google knows everything! study
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XS Update

Post  desautdw on Fri 14 Sep - 17:16

Tins painted almost ready to put back together.

[img][/img][img][/img]


Need a bit more work on electrical, but with items cleaned and repainted nearly ready to start rebuild.

[img][/img]
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Update- Delayed!

Post  desautdw on Sun 16 Dec - 19:46

Since my last posting in September, my girlfriend and I moved back home to Oklahoma. In the move the tank got scratched, so has to be redone, but electrical is almost totally done and parts are going back on as I have time. Smaller garage is a real issue, but also have plans to build a shop next spring. Longer riding season than in Idaho (much longer) so that is good. Stay tuned!
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Status Update

Post  desautdw on Wed 6 Mar - 18:07

Been cold here so working on plans for new garage. The keys to the XS650 were lost in the move and I was about to drill them out, but went back for a visit and found the keys in my old garage (my daughter and boyfriend are renting it). Also been looking for a part-time job to help pay for it all. I set up a page on facebook with photos covering my years of riding. Check it out if interested for photos and stories of rallies, bikes and all the things motorcycle related about my years as a rider. Dave's Cycles should get you there if link doesn't work: http://www.facebook.com/#!/pages/Daves-Cycles/500962569965938
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Update of XS 650

Post  desautdw on Thu 7 Mar - 22:48

Here is the latest photos. Switch gear installed, but need to fix paint damage from move and finish pipes. Electrical still not 100%, but coming together.[img][/img]

[img][/img]
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True Confession - XS 650

Post  desautdw on Thu 28 Mar - 16:18

OK, I admit it, I have not done very much to finish the XS 650. Run into electrical snags that will take time to sort out, shipping damage and household chores that have sapped by energy to tackle the job of finishing the Yamaha. But I saw someone post the idea that the way to push yourself to finish was to publicize your project and status so others will be depending on you to finish. So I also put this project on my facebook page and hope to get more feedback. My big problem is that when I plugged the new handlebar switches in, all my electrical response when key is turned stopped and nothing since. I was stupid and didn't check after every connection, so I have no idea which of about 20-30 is the problem in the rats nest of wires behind the head light. As it gets warmer, I am hoping I will be able to go through the process of elimination to figure it out. Here is my motorcycle story page.

https://www.facebook.com/#!/pages/Daves-Cycles/500962569965938
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Motorcycle Journey in 1918

Post  desautdw on Sat 30 Mar - 4:17

I wanted to share a story from my fiance's family of her great uncle. He, his wife and son joined with a friend and his wife and child drive from Hinton, Oklahoma to Mexico, Kentucky in 1918. The observations of Ethel (her great aunt) on the road show observations and views of rural US on two-wheeled (plus side car) adventures. See link:

https://www.facebook.com/#!/pages/Daves-Cycles/500962569965938
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Success!

Post  desautdw on Fri 12 Apr - 20:53

Found the major electrical snafu was a miss-installed blade fuse and ground wire just touching, no I got all my electrics but headlight going. That is major progress and means that my wiring problems are just somewhere between switch and headlight as all other lights and accessories work! Engine also cranks over. I could actually get it running at this point and may go that direction first. Starting to see the light at the end of that tunnel.
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Re: Yamaha XS 650

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