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  1. #1

    Default xs650 hardtail bobber - FIRST TIME Building.. anything..

    Hi, I'm a 20 year old kid from the Netherlands and I am building a yamaha xs650 bobber. I don't have any experience with building motorcycles so it's quite a challenge.

    I bought a hardtail frame and a front fork, then I bought a 21 inch front wheel and a 16 inch rear wheel.

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    I bought a xs650 engine, I know it runs cause I've seen it in action
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  2. #2

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    I'm crafting my own custom seat because I wasn't happy with the solo seat I had bought..
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    I want to make the back of the seat a bit shorter but that can wait.. I want to craft a custom exhaust system. That way I get a bit closer to firing the engine

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    I bought the tc-bros exhaust kit...from a dutch chopper store.. so maybe it's not the real deal.. The pipes where allready starting to rust.... is there anything I can do to get rid of the rust ?

  3. #3

    Default

    Can you weld pipes with a electrode welding machine ? I don't have a lot of welding experience so maybe I'll just hire somebody to do it for me.. but I want to learn to weld real bad.

  4. #4

    Default

    That's a very good start for a build, one thing you might check is if there are bits of plastic in the oil filter. It's a very common problem on these bikes for the cam chain guide/tensioner to go out, I just finished replacing both of mine and the rockers arms, lapped the valves and did a few other things.
    Last edited by StrawbellyJam; 06-28-2014 at 7:44 PM.

  5. #5

    Default

    Thank you sir The guy from whom I bought the engine just replaced the cam chain thanks for the tip I'll definitely look into it

  6. #6

    Default

    While am very busy with the exhaust system, I'm also working on my builds wiring.. and wow.. that is hard.. I bought supposedly NEW 1972 wiring... but it turned out it was the wiring of a 1976 Xs... so the wires didn't fit colour wise... So now I'm trying to decide if I should buy XS 1972 wiring from a german store.. Or if I am going to make my own wiring.... What should I do ???? Can you guys help me ?

  7. #7

    Default

    I bought most of my replacement parts from MikesXS, he has pretty much everything you might need.

    Here's a link to some wiring harness's if you're looking for one. They even have some simplified ones from TC bros.

    http://www.mikesxs.net/products-78.html#products

  8. #8
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    Default

    pma charging system and pamco ignition is definitely the way to go. it makes everything real simple

  9. #9
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    Wiring is fairly simple even with no electrical experience. Does take a bit of due diligence, though. Figure out what you want to run electronic wise. Study some wiring diagrams and wire it yourself. No need to buy a wiring harness pre made. You will be splicing into that most likely anyways. Do all your fabrication work first and then wire so you don't get put off by it. Will give you time to think about the electrical system.

  10. #10
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    Are you planning on running all the legal stuff, turn signals, horn, etc or just very basic wiring? Also for the exhaust it bare metal so it's going to rust especially during the summer as humidity goes up. My project looked all silver and shinny all winter, but within 2 weeks of spring there was rust everywhere. As far as doing the welding yourself I'm not sure learning on an exhaust is where you want to start, especially stick welding, all you will end up doing is punching and filling holes in the pipe. You might be able to tack it with stick and have an experienced welder finish the job, but even then you are probably going to burn holes in the pipe just striking an arc.

  11. #11

    Default

    @ember Alright thankyou, I'll give it a shot

    @ato Well I want to ride my bike every day.. so I am going to run turn signals, not sure about a horn though, I was affraid I might weld holes into the pipes, so now Im gonna have an experienced welder to the job thanks Ato

  12. #12

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    Finished fabricating the exhausts, just ignore all the ducktape
    Last edited by commanderalphanl; 06-29-2014 at 10:27 AM.

  13. #13

    Default

    Now I'm going to focus on my bikes wiring, I want to run turn signals, a 3-way ignition switch so I can ride with and without the lights on.. and that's it... should I just buy the tc bros harness ? http://www.mikesxs.net/product/19-0411.html

  14. #14

    Default

    What kind of a carb do I have? it needs two gascable, and has only 1 choke.. I cant upload any pictures...........

  15. #15
    Jetblack
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    Default

    Welcome aboard and you are definitely in the right place for chopping.

  16. #16
    Jetblack
    Guest

    Default

    Quote Originally Posted by commanderalphanl View Post
    Now I'm going to focus on my bikes wiring, I want to run turn signals, a 3-way ignition switch so I can ride with and without the lights on.. and that's it... should I just buy the tc bros harness ? http://www.mikesxs.net/product/19-0411.html
    See the chopped wiring diagram sticky at the top of this forum for modifying your current wiring... no need for after market unless you want it.

  17. #17
    Jetblack
    Guest

    Default

    If you have no idea about the carbs it tells me you really need a shop manual here yah go http://biker.net/650parts_index.html

  18. #18

    Default

    Thanks Jetblack ! I'll look into it !

  19. #19

    Default

    Can you make your own wheel spacers out of a steel pipe ?

  20. #20
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    Wheel spacers should be a snug fit to do their job properly. There is no way that pipe has the right dimensions, you may find tubing, but to do it right you'd still need a lathe, and at that point you're not saving much time over just making them perfect from scratch.

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