1972 Yamaha XS2 (XS650) project

[Wired1]

Just starting another restoration project and this time have one of my all-time bucket list bikes to make pretty again, the XS650.
I bought this machine a couple of weeks back off Trademe and it turned up on Friday. I have had a saved search for an XS650 and it just popped up and after about five minutes talking to the importer Laurence, I knew it was either buy it for the full asking price or watch someone else whip it out from under me so I just bought it.
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The bike starts well and runs rich - probably due to those hideous pipes - and has good compression. The electric start doesn't work yet and I almost burned the bike to the ground when I started kicking it over on account of the battery shorting out under the seat but a bit of kiwi fixing sorted that problem out.

The colour is hard to describe but think of new born baby shite and you're not far off. What the previous owner was thinking is a bit of a mystery but she'll be going back to the correct Brilliant Red just as soon as I find a good painter and the funds to get it done perfectly.
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[Akzle]

that shit's fokken sikk oi.

[Grumph]

Personally, I prefer the green of the first XS1.
Put a RIB pattern front tyre on it - maybe 100/90 section, no wider. The OE block pattern front tyre wandered like fuck and was largely responsible for the bad handling reputation.
If it hasn't got electronic ignition, fit it.
Just ride it.

[husaberg]

Just starting another restoration project and this time have one of my all-time bucket list bikes to make pretty again, the XS650.
I bought this machine a couple of weeks back off Trademe and it turned up on Friday. I have had a saved search for an XS650 and it just popped up and after about five minutes talking to the importer Laurence, I knew it was either buy it for the full asking price or watch someone else whip it out from under me so I just bought it.

The bike starts well and runs rich - probably due to those hideous pipes - and has good compression. The electric start doesn't work yet and I almost burned the bike to the ground when I started kicking it over on account of the battery shorting out under the seat but a bit of kiwi fixing sorted that problem out.
http://i58.photobucket.com/albums/g280/ExcessKiwi/Photo%205-02-17%202%2055%2057%20PM_zpsx6joc8x1.jpg (http://s58.photobucket.com/user/ExcessKiwi/media/Photo%205-02-17%202%2055%2057%20PM_zpsx6joc8x1.jpg.html)
The colour is hard to describe but think of new born baby shite and you're not far off. What the previous owner was thinking is a bit of a mystery but she'll be going back to the correct Brilliant Red just as soon as I find a good painter and the funds to get it done perfectly.

Can't seem to get photos to load, Ill add them when I figure it out...

Nice bike but that back wheel rim looks like a harley rim.
All the bright work looks in excellent condition.
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Next to the smiley faces there is a paper clip looking thing use that to attach the pictures direct from your PC.
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or from out of your photobucket like i did.:yes:

Ps when you go to edit a post you will not see that option but it will appear when you click on advanced down the bottom right of your post.
If you want to put the pictures in your post like i just did selve the down facing ^ next to the paper clip. and click where you want it.

[BMWST?]

very early in my motorcycle carreer i rode one of these.I kick myself now for not buying one.Always had a soft spot for Yamaha except for my SR 500 which i hated.I will watch with interest

[Motu]

I had an XS1 for 15 years..with out the stupid electric start and ugly disc brake. You don't need the starter...shit, mine would start idling while I was trying to find compression. Carbs are shit, put something else on. The XT750 swingarm is mush beefier, but you'll never find one, but even an RD swingarm is better. I think the XS2 has a split top yoke, the XS1 didn't, so welded on tabs and cut the yoke, then knurled the stauntions. I think the basic handling is pretty good, they just go out of shape a bit if you push them. A speedwobble at 95 mph makes a mess of the seat cover.

[husaberg]

I had an XS1 for 15 years..with out the stupid electric start and ugly disc brake. You don't need the starter...shit, mine would start idling while I was trying to find compression. Carbs are shit, put something else on. The XT750 swingarm is mush beefier, but you'll never find one, but even an RD swingarm is better. I think the XS2 has a split top yoke, the XS1 didn't, so welded on tabs and cut the yoke, then knurled the stauntions. I think the basic handling is pretty good, they just go out of shape a bit if you push them. A speedwobble at 95 mph makes a mess of the seat cover.

Pretty sure the XS2 had a better frame geometry than the XS1, from memory Yamaha relented and flew in Percy Tait works rider and factory tester to make it steer like a triumph.
Funny enough a lot of people used to put in XS650 swingarms into RD as they were a little longer. I never knew they used to do the opposite as well.
The Xs2 likely has slightly larger fork stauncions as Yamaha tended to change them all at the same time.

[Wired1]

Thanks Husaberg, I'm getting it slowly.
The back rim is a 16"and should be an 18"but it'll be a while before I find the correct one I'm guessing.
I will get the electric start working since it is there, first up I need to get the frame certed as it has a bit of damage from the previous owner in the States.
The same guy who painted it Brown also fitted a solo saddle then cut it off and left a few scratches on the frame that the border guys didn't like so it's a bit of welding and wallet-opening but not a major.
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[husaberg]

Thanks Husaberg, I'm getting it slowly.
The back rim is a 16"and should be an 18"but it'll be a while before I find the correct one I'm guessing.
I will get the electric start working since it is there, first up I need to get the frame certed as it has a bit of damage from the previous owner in the States.
The same guy who painted it Brown also fitted a solo saddle then cut it off and left a few scratches on the frame that the border guys didn't like so it's a bit of welding and wallet-opening but not a major.
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Mikes XS site i guess for a rim, its highly likey the rim was shared with a lot of other Yamahas they are likely available on ebay NOS or new if you look arround enough.

[Wired1]

Yep I already have a small parcel on the way from Mikes with brake pads, shoes and the left hand switch block in it.
Postage is always a killer from the States but if the right parts turn up I'll forget that pretty quickly.

If anyone out there has an XS650 could you post a photo of the under seat catch please. Mine has been munted when they fitted the solo saddle and I'd like to put it back to correct. This is the view under the seat at the moment - a bit ugly...
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[Grumph]

Mikes XS site i guess for a rim, its highly likey the rim was shared with a lot of other Yamahas they are likely available on ebay NOS or new if you look arround enough.

36 hole WM3 X 18 Common as muck. Don't think OE was even marked as Yamaha. Spoke sets are probably still available too.

[husaberg]

36 hole WM3 X 18 Common as muck. Don't think OE was even marked as Yamaha. Spoke sets are probably still available too.

I wasn't actually sure if it was 1.85 or 2.15X18 but i looked yes it is WM3 or 2.15 in metric speak
I had a look on the rims on my samilar Year RD350 and yes just the Takasago logo and rim width.
Spokes are cheap on ebay the NOS rims are certainly not, But plenty off trail bikes as well as road bikes had those same size and make rims so plenty of options.

[Motu]

Looks like it's been a streettracker, they cut the rear of the frame off to fit the tracker seat.

[Wired1]

Looks like it's been a streettracker, they cut the rear of the frame off to fit the tracker seat.

They might have been thinking that way but never got that far thankfully. The damage is only superficial and only on the top of the frame rails, the tubes are still in tact. It looks like someone welded a bar across between the two frame rails then changed their mind and cut it off again. The certifier is calling in on Friday so I'll see what he thinks.

Thanks also for the parts link Husaberg I have added that to my archives, but the part I am looking for is the bit on the frame that the catch catches on, I have the rest of it still attached to the seat. When the muppets hacked at the frame they cut off the bit the latch hooks onto on the frame. I'm hoping someone here has an XS650 and can take a photo of the bit I have to re-fabricate. Searching on the interweb for a photo hasn't turned up anything yet.

[husaberg]

They might have been thinking that way but never got that far thankfully. The damage is only superficial and only on the top of the frame rails, the tubes are still in tact. It looks like someone welded a bar across between the two frame rails then changed their mind and cut it off again. The certifier is calling in on Friday so I'll see what he thinks.

Thanks also for the parts link Husaberg I have added that to my archives, but the part I am looking for is the bit on the frame that the catch catches on, I have the rest of it still attached to the seat. When the muppets hacked at the frame they cut off the bit the latch hooks onto on the frame. I'm hoping someone here has an XS650 and can take a photo of the bit I have to re-fabricate. Searching on the interweb for a photo hasn't turned up anything yet.

Google xs2 rebuild
threads like your own one here are often full of detail pics.
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i googled up a service Xs2 manual but the pics are too fuzzy.
https://thexscafedotcom.wordpress.com/2012/01/14/xs650-xs1-xs2-tx650-tx650a-service-manual-1970-1974/
Also if you have a look at the frame parts fiche it might help.
https://thexscafedotcom.files.wordpress.com/2014/07/xs1-xs1b-f-xs2-parts-lists.pdf
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Period road test done by the likes of cycle or Cycle world also occasionally had pictures with the seat up.
Another great sourse is ebay just google the XS2 frames for sale they often have very good pictures.

[Wired1]

I met with the certifier on Friday and he inspected the frame damage and took lots of photos. The repair will be straight forward as it is only minor damage to the top of the frame rails and he just said to build it up with the mig and smooth it off so it looks like it never happened - common sense really.
So I stripped out the back of the frame and I'll start welding this week maybe.
I had to take the front master cylinder off anyway so I figured I may as well whip off the forks and do a temporary paint job on the headlight bucket and ears. I will paint the tank as well before I register it to make sure it gets registered as red and later on I'll get them all painted the correct brilliant red and white when I find a half decent painter who's not high on thinners all the time and can paint a straight line :)
The certifier recommended getting the bike registered before I strip it down for a rebuild in case the rules change later so I will register it then put it on hold.
To register it I need to fit indicators, fix the front brake, get the speedo working, and shut the damn thing up a bit. It is currently at about 90 dB idling and well over 100 at 3000 RPM so I need to get it below 90 dB at 3000. Long term I will replace the two-into-one-exhaust so if anyone wants to go a lot louder on their XS650 give me a call and I'll be happy to sell you this exhaust.
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[Wired1]

What does this thing do? Is it the safety relay?
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[Wired1]

It's listed on Trademe here: http://www.trademe.co.nz/Browse/Listing.aspx?id=1263350734
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The new system is going to cost me about $800 I figure from MikesXS in the states so this will help out with the shipping and exchange rate.

[Wired1]

Repaired the damage to the frame today, built it up with the MIG and ground it back down. Mostly with the flapper emery disk on the grinder and an air sander I bought this week - very handy tool for getting to those hard to reach places.
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[Wired1]

I wanted to do a quick test ride before I started work on the bike but unfortunately the battery is a bit tall and the poles are the wrong way around so it shorted on the underside of the seat...
Video here: https://youtu.be/Lo6q6dG16xc

[AllanB]

With that smoke I thought it was one of Ed's fancy batteries .....

Side stand!


I quite like that fat 2-1 pipe.

[Wired1]

Yep bit of a brain fart with the side stand, luckily I was turning right.
The pipe is for sale on Trade me closing tonight: http://www.trademe.co.nz/Browse/Listing.aspx?id=1263350734

[Edbear]

With that smoke I thought it was one of Ed's fancy batteries .....

Side stand!


I quite like that fat 2-1 pipe.




I heard that! :lol:

[Wired1]

I heard that! :lol:

What is the right battery for this? It should be positive on the left and a bit shorter than this one I'm picking - then again mine is a bit shorter now :)

[Edbear]

What is the right battery for this? It should be positive on the left and a bit shorter than this one I'm picking - then again mine is a bit shorter now :)

The 14A5 is the recommended battery, measures 134L x 160H x 80W.

[Wired1]

The 14A5 is the recommended battery, measures 134L x 160H x 80W.

Yep that explains the height problem, this puppy is about 175mm high with the terminal bolts being the highest point.

[Edbear]

Yep that explains the height problem, this puppy is about 175mm high with the terminal bolts being the highest point.

That's a tall one alright! :confused:

[Wired1]

The temporary paint job is coming along nicely, looks so good it will probably stick around for a while until later in the project.
Makes it easier to avoid garking the proper job before I've finished anyway.
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[mossy1200]

Nice work. You made me go tinker in garage.

[jasonu]

I wanted to do a quick test ride before I started work on the bike but unfortunately the battery is a bit tall and the poles are the wrong way around so it shorted on the underside of the seat...
Video here: https://youtu.be/Lo6q6dG16xc

Nice shed.

[Wired1]

This weekend I got the front brakes working again. The bike came with a seized front caliper, faulty master cylinder missing the cap and all locked up, and blocked brake hoses. It's hard to believe it was ever working grrrr. But I got a new caliper, master cylinder and set of hoses from Mikes and after about an hour of filling and bleeding got it working half decent last night.
I also met with the certifier dude who passed my frame repairs so now all I need for registration is the indicators and muffler - both of which are in customs waiting for payment - and then I can run her through for a warrant.
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I also repaired the battery box and managed to rebuild the missing metal taken out when the solo saddle cross member was added. Got the tool kit for a 1970-something Yamaha off Turdeme in very good condition and close enough to the missing original kit.

[Wired1]

The new header pipes and mufflers arrived on Thursday and I fitted them Friday night. Got them from Mikes XS and they cost about a grand with shipping and GST added on but they fit perfectly lining up with all the stock mounting holes. The headers are thick wall and the finned clamps are very high quality.
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The new indicators were in the box from Mikes as well so I fitted them and wired them up today. I still have to finish the headlight then she will be ready for Vinning.
I took it for a ride up the road last night and it must have looked pretty weird with all the wires sticking out the headlight, I also forgot to adjust the back brake which was a bit of excitement but the new front brake saved me and passed testing. Sounds good, I'll post a video of the new sound, you can hear yourself think now when you are riding it.

[ellipsis]

...thank fuck for people like you...:niceone:

[Akzle]

fucken oats. rbgiafp.

[Wired1]

I've been away for a couple of weeks and while I was away the left switch block arrived in the post from Mikes XS and that was the last part I needed to get the bike ready for Vinning so yesterday I fitted the switch block and took it down to the local VTNZ for inspection. They kept it overnight and today the inspector phoned me to say it had a couple of minor things to sort out but it now had a VIN number. When I went down to collect it he said he loved riding it and was impressed how well the electric start worked which was a shock to hear since as far as I knew it had never work. The guy I bought it off actually told me it didn't have electric start but it was the first XS650 model to have it. Anyway I'm stoked it starts easily on the starter and almost as easy on the kick starter.
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It failed for the front brake not working well enough so I will bleed it again and adjust the master cylinder plunger, plus the fork seals are burgered. I'm surprised I didn't notice how bad they are as the fluid is pissing out the top. I have ordered a seal kit and some other bits and pieces I will need down the track so the race is on to get it fixed and back at VTNZ within 21 days. Shouldn't be a major.

[ellipsis]

...Good stuff...looks fantastic...

[pete376403]

Is the starter control a button or a decompressor type lever? Pretty sure the first XS650 I ever saw had a decomp leter on the left bar that also operated the starter. It also had a drum front brake so a bit earlier than yours, unless the disk setup is off a later model.

[Wired1]

Is the starter control a button or a decompressor type lever? Pretty sure the first XS650 I ever saw had a decomp leter on the left bar that also operated the starter. It also had a drum front brake so a bit earlier than yours, unless the disk setup is off a later model.

Yes its the one with the decompression lever with a start switch built-in on the right switch block below the kill switch. Pretty clever stuff, you pull the lever and it lifts the left cylinder exhaust valve as well as engages the starter motor. There is also a relay that is connected to the alternator and opens the starter motor circuit when it gets to 6 volts so as soon as the bike starts it disengages the starter motor automatically. I had all the electrics off the middle and back of the bike when I was welding the frame so I'm guessing that when I put it back together I may have fixed an earth fault or poor connection.

My bike is the XS2 which is the first one they fitted electric start to and mine is the US model with a single disk front brake. The XS1 was drum front and no electric start and it is possible the european XS2 was drum front.

[suntrakr]

How'd you line up your certified? I've got an '81 xs650 I brought in from the states a couple of years back. Have been bringing up 2 young boys so haven't had the time to get on the road......until now. It's heavily modified cafe/st tracker which is in need of very/vin so just starting to look into it. I've done most of what I know already ...e mark lights etc, chain guards...any tips for process of vining?


Sent from my iPhone using Tapatalk

[suntrakr]

Love the original xs btw.


Sent from my iPhone using Tapatalk

[Wired1]

How'd you line up your certified? I've got an '81 xs650 I brought in from the states a couple of years back. Have been bringing up 2 young boys so haven't had the time to get on the road......until now. It's heavily modified cafe/st tracker which is in need of very/vin so just starting to look into it. I've done most of what I know already ...e mark lights etc, chain guards...any tips for process of vining?

I went to see VTNZ the day I picked up the bike and spoke to the motorbike inspector there. There are only a couple of guys who can cert repairs here and the guy I used was recommended to me by VTNZ so I went with him. I have used him once before when I was building a beach buggy and that time it cost me about $1500 for a full low-volume cert. The bill from him for certifying the frame repairs on the XS2 is about $200 and was very minimal, two visits to my shed, a few photos and writing up a report for VTNZ. I would guess you are going to need a bit more than that with a modified bike as they will be looking at the frame integrity after the mods. I'd start with the VTNZ or LTSA agent, they should have a list of suitable guys and up there you should have a certifier who specialises in motorcycles.

[husaberg]

I went to see VTNZ the day I picked up the bike and spoke to the motorbike inspector there. There are only a couple of guys who can cert repairs here and the guy I used was recommended to me by VTNZ so I went with him. I have used him once before when I was building a beach buggy and that time it cost me about $1500 for a full low-volume cert. The bill from him for certifying the frame repairs on the XS2 is about $200 and was very minimal, two visits to my shed, a few photos and writing up a report for VTNZ. I would guess you are going to need a bit more than that with a modified bike as they will be looking at the frame integrity after the mods. I'd start with the VTNZ or LTSA agent, they should have a list of suitable guys and up there you should have a certifier who specialises in motorcycles.

Most of the hot rod clubs have there own cert guy.
Not sure if they can do both cars and bikes?
But $200 is cheap for that.

[Wired1]

Yep $200 is a bargain but there was very little to certify, just a few grind marks on the frame rails.
Got the lights working again and re-bled the brakes so just waiting for the fork seal to arrive from Mikes XS... patiently.

[suntrakr]

I went to see VTNZ the day I picked up the bike and spoke to the motorbike inspector there. There are only a couple of guys who can cert repairs here and the guy I used was recommended to me by VTNZ so I went with him. I have used him once before when I was building a beach buggy and that time it cost me about $1500 for a full low-volume cert. The bill from him for certifying the frame repairs on the XS2 is about $200 and was very minimal, two visits to my shed, a few photos and writing up a report for VTNZ. I would guess you are going to need a bit more than that with a modified bike as they will be looking at the frame integrity after the mods. I'd start with the VTNZ or LTSA agent, they should have a list of suitable guys and up there you should have a certifier who specialises in motorcycles.

Cool. Thanks for the info, have made note of it for when I'm ready to cert.

[bistard]

I've been away for a couple of weeks and while I was away the left switch block arrived in the post from Mikes XS and that was the last part I needed to get the bike ready for Vinning so yesterday I fitted the switch block and took it down to the local VTNZ for inspection. They kept it overnight and today the inspector phoned me to say it had a couple of minor things to sort out but it now had a VIN number. When I went down to collect it he said he loved riding it and was impressed how well the electric start worked which was a shock to hear since as far as I knew it had never work. The guy I bought it off actually told me it didn't have electric start but it was the first XS650 model to have it. Anyway I'm stoked it starts easily on the starter and almost as easy on the kick starter.
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It failed for the front brake not working well enough so I will bleed it again and adjust the master cylinder plunger, plus the fork seals are burgered. I'm surprised I didn't notice how bad they are as the fluid is pissing out the top. I have ordered a seal kit and some other bits and pieces I will need down the track so the race is on to get it fixed and back at VTNZ within 21 days. Shouldn't be a major.

Nice work, one thing I have never understood with the whole VIN process, is you are not allowed to modify the frame, as you pointed out, you had to repair a previous mod to the frame & then the inspector drills holes in the frame & pop rivets the plate to it, is that not modifying the frame???

[Wired1]

Yeah I had to laugh when I saw the VIN number pop rivetted on. I'll be taking it off for painting too :)
He did say it was one of the weakest fails he had seen for a while and if it hadn't been noticed at the border he wouldn't have required the cert.
It should be like repairing a building, ie not needing a building consent if you are only repairing it not altering it or building it from scratch.

[AllanB]

Nice work, one thing I have never understood with the whole VIN process, is you are not allowed to modify the frame, as you pointed out, you had to repair a previous mod to the frame & then the inspector drills holes in the frame & pop rivets the plate to it, is that not modifying the frame???

Had - new bikes have the same holes and VINs from the factory - still ruffles me that my Ducati factory Vin plate is not hidden under the seat or somewhere discrete. No, it's placed smack on the lovely trellis frame.

[Wired1]

Well I'm stranded in Wellington on Easter and it looks like I'll be stuck here until Saturday thanks to Air NZ so I've been making use of my down time to edit my latest video covering the removal, repair and replacement of the forks.
The video is here: https://youtu.be/rGJQsVt-918
I've also fixed the faulty tail light and worked out how to adjust the front brakes to make them work effectively.
I should have been home at lunch time today so I was planning on taking her in for a re-test today but I guess it will have to wait until next week now.

[jasonu]

Well I'm stranded in Wellington on Easter and it looks like I'll be stuck here until Saturday thanks to Air NZ so I've been making use of my down time to edit my latest video covering the removal, repair and replacement of the forks.
The video is here: https://youtu.be/rGJQsVt-918
I've also fixed the faulty tail light and worked out how to adjust the front brakes to make them work effectively.
I should have been home at lunch time today so I was planning on taking her in for a re-test today but I guess it will have to wait until next week now.

Men in sheds. Great stuff!!!

[AllanB]

Mate I'd have buffed up those lower fork legs while they were off.

Nice video. Basic stuff back in the day those forks. I had several bikes with lower fork leg drain bolts.

[suntrakr]

Great video. You've moved the camera around well and edited it up nicely. Bit of time involved to get a result like that.


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[Wired1]

Been a good week this week. After getting stuck in Wellington over Easter I got home Saturday and did some final adjustments and tweaking on the brakes the took the bike into VINZ on Tuesday for it's re-inspection. I was expecting to drop it off an pick it up later but the inspector took it for a ride around the block as soon as I got there then told me to load it up while he did the paperwork. So today I fitted the number plate, rego and WOF and went for a couple of rides.
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It is missing a wee bit in the upper ranges and running a little rough but I haven't adjusted anything yet or cleaned out the carbs and it probably hasn't had a decent ride for a year or two. I got a full year of rego as it is only $120 for an old girl like this, and the plan is to ride it around for a month or two before it gets too cold. After that I'll start tearing it down for a full resto ready for summer.
The new video is here: https://youtu.be/QEo3mR6KaDE

[ellipsis]

...:banana::banana::banana:...yahoo...so cool to see a thing of beauty coming back into the world...

[Intruder VS]

Awesome work and love the video. Looking forward to future updates:2thumbsup