My 80 XS650 Project - First Motorcycle - Period

bigjimmyw13 · Last edited by bigjimmyw13 on December 9, 2009, 6:55 pm; edited 3 times in total

Alright guys. I bought a 1980 XS650, running well whenever I bought it. Of course it doesn't run now because it's in 1,000 pieces. So here we go!

P.S. Sorry I didn't have the forethought in taking pictures of the bike before I started stripping it. So just imagine a stock 80 XS650 Special II.

Right now I'm trying to find a wiring schematic and help on wiring a NO battery bike.... Any suggestions? Anyone near College Station, TX willing to help?

bigjimmyw13 · Posted: November 19, 2009, 9:27 pm Post subject: Re: My 80 XS650 Project

More pics

1ironhead · Posted: November 22, 2009, 10:53 pm Post subject: Re: My 80 XS650 Project

Looks like you got a jump on your winter project.Looks like you might need another before winter's end.Did you rake the neck?

bigjimmyw13 · Posted: November 23, 2009, 1:11 am Post subject: Re: My 80 XS650 Project

Sure did! To accept +4" fork tubes. Yeah well I actually have another project on the back burner. A 1979 CX500

ore pics though. I'm assembling it to get an idea of where I need to make welds and placement of things before powdercoating the frame and other parts. Gloss black on the frame and flat on the accents.

Like I said before though. I'm still nervous about the wiring. That is something I'm very unfamiliar with. I guess I better get familiar with it huh?

bigjimmyw13 · Posted: November 23, 2009, 1:14 am Post subject: Re: My 80 XS650 Project

More pics continued.

bigjimmyw13 · Posted: November 23, 2009, 1:18 am Post subject: Re: My 80 XS650 Project

And More. Remember this is just for figuring things out.

danxs650mass · Posted: November 23, 2009, 4:29 pm Post subject: Re: My 80 XS650 Project

looks good what kind of exhaust pipes are those i like the way the look

bigjimmyw13 · Posted: November 23, 2009, 4:42 pm Post subject: Re: My 80 XS650 Project

The pipes came from mikes xs. I'm leaving them that length the only thing I'll do to them is heat wrap them. And of course mount them.

The next step is to mount the extended forks. I'm just waiting till they get back from powdercoat and reassembled. Which is hopefully Tuesday (24th) or Wednesday at the latest.

mmasac · Posted: November 23, 2009, 10:32 pm Post subject: Re: My 80 XS650 Project

Project looks good so far, good work. keep us updated.

Dirka · Posted: November 23, 2009, 11:31 pm Post subject: Re: My 80 XS650 Project

i dig the fact that you are building this in your dining room!

bigjimmyw13 · Posted: November 24, 2009, 12:31 am Post subject: Re: My 80 XS650 Project

Yeah you like that? I was going to do it in the spare bedroom, but I figured I'd end up ruining the carpet sooner or later.

Anyone want to make some adapter plates for my forward controls? I have a stencil for what I need. Very Happy

Picked this up on Egay
cgi.ebay.com/ebaymotor...MEWAX%3AIT

I know it's not very original, but it was cheap (compared to new) and it leaves the option open to run the bike rear fenderless.

bigjimmyw13 · Posted: November 25, 2009, 3:10 am Post subject: Re: My 80 XS650 Project

Alright after following a thread over at the Garage I have ordered some parts to set up a Permanent Magnet Alternator.

On top of that I'm going to be putting an order into Mikes for a Pamco High Output Ignition kit with the advance set up included. So that way I can run this babe without a battery.

As of right now though I do have one question. Am I correct in thinking that I will have to crack the case to install the Pamco kit? It says that I need to install bushings and a seal (included) and if I'm not mistaken these go on the camshaft?

I hope I don't have to crack the case, but if I do then it will at least give me the chance to powdercoat the cover and install the performance camshaft.

650skull · Support Staff Joined: Jul 19, 2007 Posts: 1186

If you want to install another cam then the head has to come off, (remove motor). ................If you are installing the advance weight's rod the Take off the shiny covers, Cam Covers), off the end of the cam..install the bushings inside the cam, (no removal of the seals will be needed), Grease the shaft, (Put a bit of grease in the cam before installing the shaft), and slide in through the Cam making sure the Pamco will be on the right hand side and the advance weights will be on the left..........That is sitting on the bike

despecial · Posted: November 25, 2009, 4:33 am Post subject: Re: My 80 XS650 Project

- i used something similar to this for my batteryless pamco setup

- alternator - RD350 permag
- ign unit - pamco
- capacitor - 25V, 10000uF from a KTM with screw fittings
- this diagram is missing the 2nd brake light switch, horn and blinkers, all simple additions

bigjimmyw13 · Posted: November 25, 2009, 4:43 am Post subject: Re: My 80 XS650 Project

Wow. Thanks a lot guys. I think I am FINALLY beginning to capably visualize the wiring on the bike. Ok well good. If I don't have to open the case then I am not going to crack the case till I do a total engine overhaul, later down the road.

Thanks a lot skull for clarifying that for me. And despecial thanks a lot for the edited diagram. Is the RD350 a single phase stator or three phase? I picked up the Banshee bracket and rotor plus a vf500 stator with the vf500 reg/rect.

despecial · Posted: November 25, 2009, 4:52 am Post subject: Re: My 80 XS650 Project

- 3 phase LC or YPVS...no problem

bigjimmyw13 · Posted: November 25, 2009, 10:18 pm Post subject: Re: My 80 XS650 Project

Will someone do me a huge favor and take a pic of the clutch mechanism on the inside of the alternator cover?

Eric00 · Posted: November 29, 2009, 12:11 am Post subject: Re: My 80 XS650 Project

where did you find that rounded rear fender??? ive looked everywhere- lol Thanks Eric

bigjimmyw13 · Posted: November 29, 2009, 12:23 am Post subject: Re: My 80 XS650 Project

Ha... It was stock..

Eric00 · Posted: November 29, 2009, 1:37 am Post subject: Re: My 80 XS650 Project

damn i see that now, i was hoping it was a full fender you cut down, i guess my hunt goes on.....

danxs650mass · Posted: November 29, 2009, 1:32 pm Post subject: Re: My 80 XS650 Project

if you look on u tube for the xs 650 clutch theres a guy that does a good job showing how it works under the cover

bigjimmyw13 · Posted: November 30, 2009, 12:54 am Post subject: Re: My 80 XS650 Project

For some reason I can't get the front wheel to line up and stay lined up. Should the fork tubes be capable of spinning when installed on the slider?

On another note the front tire is on! Pic up

bigjimmyw13 · Posted: November 30, 2009, 11:45 pm Post subject: Re: My 80 XS650 Project

What stops me from using a "50" roller chain to replace the oem drive chain? Any reason I wouldn't want to do that?

Also is the front brake line union necessary for anything other than mounting?

Srinath · Posted: December 1, 2009, 10:50 am Post subject: Re: My 80 XS650 Project

I am running one, in as much as its on the bike which has a dead motor ... it costs like 20 bucks for a 10ft length and industrial grade stuff is often very well made and very durable.
Cool.
Srinath.

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