XS650: 2016   Leave a comment

That time of year has come again. And been. Until next time.

We trust you have embraced the new year. For some it wont be so good. Others will fare better. In the main however, you make a good part of your own luck.

I intend to quit the SR500 sidecar. Kool. But. Too small. And the XS650 sidecar is there. Should be enough stuff lying around to build a legal SR500 cafe racer. 78 frame n motor. Make some space – give me a reason to finally use the trick stuff I have lying around. Consolidate the ever growing parts collection. XStra never XSive.

The garden was good to me last year. Worried. Winter hasn’t come. The fruit trees are already beginning to bud. Too early. Too warm. The coming frosts will wreck no end of damage. All I’m doing is ruining good winter tyres. And I love playing in the snow.

Take pleasure in your projects as they evolve. Set directions rather than goals. Be open to the experiences your journey will confront you with.

So. All the best to you all. Thanxs for reading . And commenting.

Enjoy …

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Posted January 2, 2016 by xscafe in Uncategorized

XS650: Vibratirry Bowels   Leave a comment

Was cruising through fleabay and found this: …

 

Pro-1 Racing is now offering ISOTROPIC FINISH services on YAMAHA XS 650 Motorcycle Transmission . Note this is a machine shop service on your transmission. Isotropic Finishing is not a polish process but a super finishing procedure. This process is a two stage chemical process to produce a super finish know as an Isotropic Finish. The first step is a chemical interaction with the metal where a film that is 1 micron thick or 1/100000in. The parts interact with the ceramic media and a vibratirry bowel. The second step is also a chemical reaction that produces the super finish know as the Isotropic Super Finish. This two step process takes about 4-6 hours in each step with a total time of 10-12 hours. Parts are constantly inspected and measured, during both processes. After parts are finished, all parts are Ultra-Sound cleaned and coated with a rust prohibitor.

Parts received are inventoried and digital picture are documented
We would like to have the transmission disassembled if possible,we offer services to remove gears from shafts for an extra charge.
We inspect parts parts and advise if we see issues

We use BV products from Melbourne Australia. I acquired all of the knowledge and procedures during my stay there in 04/ 2015.
The experience was very exciting and I’m looking forward to share all of the beneficial results.

Benefits

• reduces friction,vibration and noise
• improves Shifting on Vintage bikes and Harley Davidson’s
• Race bike application
• longer life on parts
• reduces lubricant temperatures
• reduces metal to metal pitting
• less inertia= lee friction=reduces fuel consumption
• stress relieves parts

Applications include

• gears and shafts
• camshafts
• crankshafts
• rocker arms
• valve springs
• transmission gears

For more information, please feel free to call;
Short Block Charlie/ Pro One Racing at ### ### ####.

 

 

sorry Charlie, your block’s shortness could have something to do with your vibratirry bowel

In essence this is a vibration finishing process. Uses non-abrasive media. On chemically coated machined parts. Creates a non-directional finish. Removes stress risers. Improves surface finish and edges.

Main benefits seem to be stress relief, reduced friction, less heat.

Isotropic Finish is related to the non-directional vibration finish. The chemical treatment serves to speed this process up

BV Products actually do exist. Couldnt find any medical warnings on their site.

Posted December 28, 2015 by xscafe in Motor - Gearbox, Uncategorized

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XS650: XS’ive   Leave a comment

I have played many sports. Some to a high level. Kinda normal when you grow up in ‘godzown’ land. Of them all, rugby, sailing, surfing and fishing were my favourites. And I discovered motorcycles.

As a kiwi, rugby is part of your soul. Whether you like it or not. The Springbok tour of 1981 tested the limits of kiwi social conscience. And through their actions, the NZ Police lost, forever, the respect the NZ population had previously given them. Police are, after all, simply the biggest gang in the world.

Like many kiwis I stopped playing and watching rugby. Totally. The working class image of Rugby League captured many, myself included.

In the late 90’s I ended up in Germany. A land with almost no rugby profile. 2007 a mate from home contacted me. Wanted to come and visit. Experience the Rugby World Cup in France. Together we rode 2 of my XS’es ca. 10000km each through France. Traveling from game to game. Reawakening my passion for rugby. Today, my son plays rugby for RKH.  Rugby Klub Heusenstamm. It is really nice to feel the passion these (?not so?) normal German families have for this wonderful game.

The 2015 Rugby World Cup tournament has now ended. The winners were, of course, Rugby.

As the celebrations ended and the dust settled we learnt that Jonah Lomu would never experience his greatest desire. To see his boys grow up.

His rugby heyday occurred during the ‘dark ages’. My self-imposed rugby exile. My loss. Greatness has a habit of transcending barriers. Lomu’s presence impacted into my world. What a League player he would have made. Later I had the pleasure of meeting the man himself. Typical of many Tongans I know. Big. And humble.

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Jonah Lomu … ?the worlds first global rugby superstar?

A day later, Richie McCaw, All Black captain, ?the world’s greatest yet rugby player? announced his retirement.

A truely sad week.

The Phoenix at work.

Posted December 1, 2015 by xscafe in General, Uncategorized

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XS650: Tappet Covers   Leave a comment

Was ratting round in my spares shelves/boxes. Found a 3-bolt tappet cover with slots instead of bolt holes – wtf?

Then found three more

Ah so! Early XS1 covers. No O-ring grooves. Gasket pure.

 

tappet covers outer

tappet covers, outside … early 3-bolt, slotted, gasket, … 4-bolt decompression cover, XS2, holes, gasket … 3- and 4-bolt cover, holes, gasket … 3- and 4-bolt covers with holes and an o-ring groove cut – 1 set alu, 1 set chromed

 

 

tapppet covers inside

tapppet covers inside … here you can see the flat gasket faces and the grooved o-ring covers

 

 

.

 

Posted October 15, 2015 by xscafe in Motor - Head

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XS650: School Time   Leave a comment

Our boy turned 9 the other day – how time flies!!!

He loves riding. Sidecar or as solo pillion – no problem – gotta have wind in face.

Looking for a birthday gift – Lego is always a winner. Stumbled across a bit of XS memorabilia that guaranteed not many have.

We have summer school break at the moment. 6 weeks of it. He had a week of football camp with Real Madrid and another week with his rugby club. The rest I have him on my construction site.

Anyway, to cut a short story long, I was looking for birthday stuff – school in mind – just the stuff kids hate. And found this …

 

1 ..  kool XS2 Pencil Case

kool XS2 Pencil Case

 

2 .. with 2 pockets

with 2 pockets

 

Sure it’s used. Has a name inside with a post code that doesn’t exist anymore. But, hey, for a kid that goes to school in a sidecar it’s kinda fitting.

Posted August 20, 2015 by xscafe in General

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XS650: Fork Lowering   Leave a comment

Some time ago I posted ‘How to lower those Forks‘. Have always had misgivings about this method – it reduces the ammount of fork travel. OK if you dont push your bike.

It is true that our XS650s do suffer from posture. Front is a bit high/rear a bit low.

My blue rat runs an SR500 front drum brake. One of my SR500s runs with an XS650 fork.

Comparing the XS650 and SR500 upper yokes you can see marked differences. And similarities. Fork width and tube diameters are the same. Yoke height isnt. SR500 front sits lower as the yoke is flat.

 

1 .. unpainted SR500 upper yoke – painted XS650 one … (SR500 yoke has been a little modified-handlebar has been solid mounted and instrument cluster mounts have been remove

unpainted SR500 upper yoke – painted XS650 one … (SR500 yoke has been a little modified-handlebar has been solid mounted and instrument cluster mounts have been removed) – apart from that the geometry matches

 

2 .. you can see that the XS650 yoke mounts higher than the SR500 – translates to the fork tubes sitting lower and the front higher

you can see that the XS650 yoke mounts higher than the SR500 – translates to the fork tubes sitting lower and the front higher

 

3 .. here you can see the same – the difference is about 27mm or so

here you can see the same – the difference is about 27mm or so

 

Can definitely gain over an inch (ca 27mm) height change very easily without compromising fork travel.

Posted July 15, 2015 by xscafe in Frame - Forks

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XS650: Ants’ PMA   Leave a comment

Sourced and installed the parts from an RD350LC PMA into my blue rat some years ago . Used. Old. And still good. Very happy with it.

A year or so ago I picked up a nice low mileage 77 D. Ridden a few miles every year. Complete paper record. Had some charging issues.

About this time Ants from the British XS650 forum began providing new PMA units for a good price. 200W. Complete with rec/reg, a rotor cone key that fit the original XS650 crankshaft and timing marks. (if trying the link dont be put off if you get a blank page – simply reset and it will appear – dont know why it does this but it happens to me all the time)

 

1 .. Ants’ PMA kit

 

Was pretty busy for a while and it sat. Eventually got a chance to blow the dust off and begin.

 

2 ..  Checking that the stator screws were loctited in – Yes.

Checking that the stator screws were loctited in – Yes.

 

3 ..  Sometimes this locating pin just wont come out. Easier to quickly modify the backing plate

Sometimes this locating pin just wont come out. Easier to quickly modify the backing plate

 

5 .. The pin sits at 6 o’clock so a simple line perpendicular to the horizontal gives the position

The pin sits at 6 o’clock so a simple line perpendicular to the horizontal gives the position

 

6 .. Backing plate didn’t sit properly over the crankshaft seal boss so got busy with a file. Would have been quicker to head off to the workshop and chuck it in the lathe. Naya.

Backing plate didn’t sit properly over the crankshaft seal boss so got busy with a file. Would have been quicker to head off to the workshop and chuck it in the lathe. Naya.

 

7 .. Took a little while.

Took a little while.

 

8 .. Sits perfect now.

Sits perfect now.

 

Cut-out and reshaping will be now be done during production.

 

9 ..  Phase wires held in place with a clip. Used another on the plate screw to the right just to keep clear from the chain and secured cable with a frame tie just below the rear

Phase wires held in place with a clip. Used another on the plate screw to the right just to keep clear from the chain and secured cable with a frame tie just below the rear engine mount.

 

Also removed the blue neutral indicator wire from the old loom, resheathed it in 4mm isolating sheath and reconnected to the original position. (Plug connector upper left in next pic)

 

10 .. Remove the battery to release the rectifier.

This is the original regulator. Remove it.

 

 The rectifier too. Sits under the battery box.

 

11 .. Remove the battery to release the rectifier.

Remove the battery to release the rectifier.

 

12 .. Made a plate to mount the new 5 wire rec/reg in the original reg position so the fins didn’t block the airbox inlet. Would have welded tabs directly to the battery box but had run out of wire for the MIG. The 3 screws with nuts create an air space under the rec/reg for cooling and better air flow to the filter-box. Packed with rubber bushes they dont rub against the underside of the rec/reg.

Made a plate to mount the new 5 wire rec/reg in the original reg position so the fins didn’t block the airbox inlet. Would have welded tabs directly to the battery box but had run out of wire for the MIG. The 3 screws with nuts create an air space under the rec/reg for cooling and better air flow to the filter-box. Packed with rubber bushes they dont rub against the underside of the rec/reg.

 

13 .. Fits snug between the tool box and filter-box. Cables separated, resheathed and fitted with original connectors

Fits snug between the tool box and filter-box. Cables separated, resheathed and fitted with original connectors

 

14 .. Release the original connector blocks by inserting a small flat bladed screwdriver into the recess beside the pins. Simply push out.

Release the original connector blocks by inserting a small flat bladed screwdriver into the recess beside the pins. Simply push out.

 

15 .. Make sure the tangs are reset before reusing.

Make sure the tangs are reset before reusing.

 

16 .. Added a 20 Amp flat bladed fuse holder in the positive battery feed. Just for security. This wire is too long and will be reworked.

Added a 20 Amp flat bladed fuse holder in the positive battery feed. Just for security. This wire is too long and will be reworked.

 

The rec/reg, when mounted on the plate, interferes with the sidecover. Modified an old sidecover. Rattlecan-blacked it and it’s mate. Be a shame to mess up a good set of covers

Just got to put some kms on her now to road test before installing a 750 kit that’s been sitting on the shelf for a couple of years.

Had some charging issues in the beginning. Went through and checked the new wiring. Not quite sure what was wrong but the issues disappeared.

More than happy with this.

Update … almost killed my second rear tyre now – no problems – running sweet

Ant’s: This is a good product – once I installed it, 2.5 years ago, I have had no problems .. !!KOOL!!