1972 Yamaha XS2 (XS650) project

[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.

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.

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...

[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.

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?


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[suntrakr]

Love the original xs btw.


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[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.

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???