1981 Yamaha XS650 Bobber Project

[blk05spec]

I started this project around the end of last summer.

So far I have:
Welded on the hardtail
black leather solo seat
Harley superglide tank
custom forward controls

Originally it was going to be a budget build, but thats out the window, in a week or so I'm ordering all the parts needed to finish it and make it exactly how I want it.

Parts to be ordered:
DNA Springer front end in matte black -2" length
DNA Springer matte black front 4 pot brake.
21x2.15 Front wheel, 16x3/3.5 rear wheel (need help deciding on color)
New seat (not sure if I want to do tan leather with something custom "engraved" on it, or crocodile skin or something)
Fake oil tank for the electronics
new solo seat rear mounts
16" Black mini apes
Matte black headlight for the springer front
Side mount Cadillac style taillight with plate mount
....I'm sure theres more....

Powdercoater is going to be busy, but I'm still in the air about colors.

Option #1: Matte Black frame, Gloss black tank and rear fender. In this case, I would want to throw some color and polished into the wheels, maybe black wheel w/ chrome spokes, or all red wheels.

Option #2: Matte Black frame, Blood red metallic tank and fender. All black wheels, possibly with blood red spoke nipples.

Option #3: Matte Black frame, Metallic blue (sorta like RSX/STI blue) tank and fender. Again, all black wheels in the case and maybe color matched spoke nipples.

I've thought about a colored frame, but if I ever change my mind it's easier to change tank and fender colors instead of tearing down and getting the frame re-powdercoated.

On to the pictures:
The power plant:


The bike in it's current state pretty much...


My inspiration(I'll have the same front end and handlebars):


Burnout video:
[URL=http://s93.photobucket.com/albums/l73/youngguru33/?action=view&current=00101.flv[/URL]

[RJTeeter]

That thing is sexy. I need to ditch one of my bikes and grab a 650 up :Banane20:

[wafflez66]

That bike is sooo awesome :tup:

[jimmyc607]

Absolutely love this thing man and not even a bike guy. You've put alot of work into it and the attention to detail you've done is awesome. BTW let me know if you need your tins painted man, I've got a few colors of paint leftover that would be plenty for bike tins and as always I give good friends great deals especially if they do the prep work :)

[Griff]

Hell yeah! Shes headin the right direction. :tup: I was gonna build my old 650xs but she was killed by a snow plow :(
Im working on a Triumph 750 hard tail at the moment.

[blk05spec]

Griff if you ever want to get rid of that triumph you let me know lol. I want to build a trumpet so bad...

I think my next build will be buell engine based....wicked drop seat with a fat rear tire. Wish I could find an inspiration pic I found at one time...

[Griff]

Griff if you ever want to get rid of that triumph you let me know lol. I want to build a trumpet so bad...
You can find some triumphs pretty cheap. I got this one for $1200 as a basket case. The motor was supposedly just redone but only had 8000 miles on it vwith a clear title but the bike came in 5 or six boxes. Half of the stuff I was replacing with aftermarket anyhow so all I really needed was the chassis and the motor. It was already hard-tailed when I bought it but most of the welds were JB weld!!! I cut the old tail off and welded a pre-fabbed tail on off ebay. When the bikes done Ill have less than 3000 into it including everything from the chain, tires, ignition, and the bike itself.

[blk05spec]

Updates!

Old bars:



New setup: Black bars, new levers, new slim master cyl, new grips.



New front caliper/pads and stainless braided brake line:


Headlight mocked up (old Harley running light):





I'm going to pull the bike out in a few minutes and snap some overall progress pics. Then going later to buy a fender and some hardware.

[blk05spec]

Solo seat and fake oil tank(storage for the electronics):


Single carb setup being ordered tonight:

[saxon]

nice to see the project is still going on :tup:

[blk05spec]

Just ordered:
2-1 Intake Manifold
Mikuni 36mm VM Round Slide Carb w/ full jet kit
New Carb Holder Gaskets
Air filter for the Mikuni
New throttle cable
Black Face Speedo
Handlebar speedo mount

Should run GRRREEEAAATTTT with the new carb setup. The stock dual carbs are just outdated and are not geared towards performance at all. With the new carb I can rev the bike out to 9k rpm's and change the tune in a matter of minutes. It set me back a pretty penny but I think it will be well worth it.

I ran up to lowes today and grabbed some supplies to fab up the rear axle adjusters.

After those parts get installed...its on to the last steps:
-Buy Rear Fender, and fab some mounting tabs
-Fab tank mounts
-Wire all lights, horn, speedo
-Purchase and install bar end mirror
-Fab or order pipes (can run with the current ones for a little while so this isn't a top priority)
-Tear down, paint and reassemble

Oh yah and put it on the insurance and get reg/title...that should be done this week though.

[jimmyc607]

Nice Dustin can't wait to see some updated pics of this beast :)

[blk05spec]

Todays update....

Painted the small rocker covers gunmetal, just for shits and gigs to see what it looks like. Better than the oxidized mess they were before.

Welded the axle adjusters onto the frame...they aren't the prettiest thing but they'll get the job done.

Found out how I'm going to mount the tank. I'm gonna have to ditch the top motor mount to get the tank to sit right, and also relocate the petcock farther back on the tank.

Hoping to finish up the tank, besides paint, this week.

Biggest things left to do after that will be mounting the lights, and fabbing/mounting a rear fender.

Probably just going to do some odds and end things I've been putting off for the rest of the week until more parts arrive.

Goal is to have ALL required frame welding done in the next 2 weeks.

[blk05spec]

Manifold came in the mail...i'll grab some pics if I get the chance.

Carb, gaskets, throttle cable, and speedometer are expected to be here friday unless this winter storm pushes them back.

[jimmyc607]

Sweeet! :) I expect to see some pics added to the 607 bike section next week when the forums are back up and running :)

[blk05spec]

oh I will...i can't wait. I feel deprived.

[jimmyc607]

Tell me about it... although my work productivity has went up significantly LOL.

Back on topic though I definately think the single carb is going to look sick and be awesome for ya man. Like you were telling me those duals just had way too many adjustments and variables.

[blk05spec]

All the single carb conversion stuff is in. Should be going on the bike today or tomorrow, then fire it up and see how she runs.

[wafflez66]

PICS!!!!!!!!!!!!!!!!!!!!!!!!!!!!! please..................

[blk05spec]

hopefully gunna work on it sometime today.

[saxon]

pics or ban!!!

[blk05spec]

SUPER PUMPED! Got the carb all set up, ran into one snag, the fuel line isn't long enough to reach the tank but I just set the tank on the seat and hooked it up.

RUNS LIKE A CHAMP!!! I put a 210 main jet in it, as was suggested by the guy I bought the manifold from. It started up first kick with no choke, idled and revved right from the get go. My old carbs must have been horrible because its day and night how much better it is now.

No backfires. No flames. Instant throttle response. OH ITS AWESOME!

Going to have to get a new fuel line and probably going to get a new petcock because mine the reserve valve leaks fuel.

On to the pictures...

[RJTeeter]

Nice! Your making me 4-stroke jealous.

[RJTeeter]

Did you have to strip chrome off your rims before painting them black?

[blk05spec]

I just sanded them a little bit before painting over the chrome. I'm actually going to redo them here soon.

[saxon]

looking nice

[lotar_6]

sic man... nice work!!!!

[wafflez66]

I like it.

[jimmyc607]

Awesome work and progress man :)

[blk05spec]

Screamed up the street tonight. THIS BIKE SCARES ME! It is the wierdest feeling not having rear suspension, it's like instant balls to the wall power right to the ground.

There is a slight low end stutter, almost like my damn car has been doing because of the MAF. Like it's choking a little at the low end but then it opens right up and SCREAMS!

I'm gunna swap out the plugs for a new set because I figure the old carb setup really screwed them up. Hopefully that helps.

Also the float bowls are over filling like crazy. The gas just keeps dripping out the overfill tube if the petcock is open. Not sure whats up with that.

On a good note, I've found a way to mount my rear lights so those will be getting wired here in a few days. Gunna put it on the insurance and get it titled ASAP so I can ride it atleast around the block.

[RJTeeter]

Seems like that stutter issue might be something that comes along with the single carb. Less air/fuel control.

[blk05spec]

Might need to bump up the fuel some more, or down some. Not really sure. Guess I'll have to do some research on carb tuning.

[jimmyc607]

Does the carb have a hi and lo jet setting on it?

[blk05spec]

It has a main jet and a Pilot Jet. In all honesty I don't know what the pilot jet does, and I should have checked to see what size it was when I had the carb apart.

[RJTeeter]

The pilot jet generally controls fuel mixture at idle and up to 1/4 throttle.

[RJTeeter]

Ps - I didn't know. I googled it so I could sound smart ;)

[blk05spec]

Yah I just found the carb manual online. From the sounds of it my pilot jet is too small. It's recomended I run a 20-25 pilot. I have no spare pilot jets so I'm gunna have to call around.

[lotar_6]

I might still have some jets laying around... but I might have given them to the new fizzer owner... don't recall. I'll check tonight.

[blk05spec]

That would be great, let me know. I need like a 20-25 pilot jet. I think the carb brand new came jetted for a sport bike setup because the main jet was a 320 which is CRAZZZY amounts of fuel(like an 1/8th inch hole in that jet)...i had to step it down to a 210.

As long as the jets are for a mikuni they should fit.

[lotar_6]

sorry, bro... I gave them to the guy. And they were mikuni. loved and hated those carbs!

give Lane's in WG a call. they might have them on hand.

oh, not sure how your valves are set up, but I do have a mostly complete set of 7.48mm valve shims if you need some.

[blk05spec]

I'll let you know if I happen to need valve shims. Thanks for checking on the jets.

I took some video tonight of me riding up and down the street a little. And just about dumped it...

TOTALLY forgot that the battery tray was only tacked in. So it ripped off and went right under the back tire while I was doing 10-15mph or so. Just right over it, thought I was dead. Battery didn't survive but the 16gauge steel battery box is still in awesome shape.

[lotar_6]

lol... patience grasshopper.

[blk05spec]

Yah, patience isn't my greatest attribute.

Tomorrow I'm tearing it down to bare frame. Hopefully taking it to the shop and finishing ALL the welding on sunday. Then it's paint and final assembly time.

[Gforcefd]

Bike is looking pretty badass sir. Going to look really good after final assembly.

[jimmyc607]

Awesome project man congrats on getting it done and ready for the season :)

[blk05spec]

UPDATE:
BIKE WILL BE GETTING A JOCKEY SHIFTER SETUP!

I had contemplated it from the get-go. My original plan was to just mount the clutch lever right on the jockey shifter, Btout this is a very unsafe approach because in the event that you have to stop quickly, you have to remove your hand from the bars just to get the bike into neutral. And it's not easy to stop a bike fast one handed.

So a guy on the forums is making me a custom worm drive on the left side engine cover to convert the bike to a foot clutch. The left peg will now be the clutch. This will be an awesome setup!

Jockey shifter just adds to the coolness, and make it even more fun to just rip around town.

***Any ideas for the shift knob?***

[Gforcefd]

8ball. I have one you can test out and see if it works for you.

[blk05spec]

FRAME WELDING IS DONE!!! TANK IS READY TO MOUNT!!!

Once I decide what I'm doing for the rear fender, and whether mounts will need to be welded, I can send it off to get powdercoated.

I've been debating going with a colored frame and a two tone paint job on the tank and fender. It has to be perfect or I won't like it. A black frame with colored tins is easy to pull off, but if done right the colored frame can look SWEET!

Just some powdercoating to get done, then finally assembly AND SHE'S READY TO HIT THE ROAD!!!

[RJTeeter]

:tup::tup::tup:

[lotar_6]

w3rd!

[blk05spec]

Ordered:
Speedo Cable
New Pilot Jet
Couple new relays to get the signals working right
Kickstand spring & bumpstop
Bar End mirrors

Once I get the frame powdercoated and tins painted SHE IS READY TO ROLL!!!

[saxon]

where are you getting the powdercoating done at?

[92civicruiser]

where are you getting the powdercoating done at?

Same Question here...I have some larger items I would like powder coated eventually.

[blk05spec]

Terry. He has the capacity, I just need to send him pics of the frame before he'll quote me a price.

[jimmyc607]

Terry has a pretty huge oven. I've had him do quite a few pieces for me and Steph over the years and they have always came out great and he's been damn good about pricing and getting me my stuff asap :)

[blk05spec]

Current pics...



As you can tell, I still have to finalize alot of little things on the bike, clean up the wiring, etc etc....

[RJTeeter]

Oh man. THat thing is sexy. I like the bike tire mod. Do you still plan on going with the mini apes and the springer front end?

[blk05spec]

Bike tire mod???

If I do decide to go springer front and apes, I would have to do both at the same time since harley front ends have 1" bars instead of 7/8". I like the way it looks now, but I may go with some mini z-bars just for a better riding postition....The way it is now, my back hurts just sitting on the thing for 20 minutes....but I love the look of the riding position, slouched over all tucked into it. With taller bars my back will be alot more straight, which would definitely improve the feel.

[RJTeeter]

Meant to type back tire mod. Back tire mod = sweet burn out.

[jimmyc607]

Looks sick man and damn that paint is pretty :) I love the color combo and overall look you have right now... it just screams bad mofo :)

[92civicruiser]

I was never really into bikes but your build has me wanting one!

[RJTeeter]

Dooo it!!