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Old 02-05-2013, 05:38 PM   #21
SOS OP
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Joined: Jan 2008
Location: 0hio
Oddometer: 706
Coil, Muffler and Fender

I haven't been keeping the posts up too well here, but I finally got around for an update.

I had to find some place to stick the coils since the bracket had to be removed to fit the MX tank.



I almost mounted them by the air boxes, but then I decided to check the Pamco ignition instructions that is getting installed. I'm glad I did because the Pamco requires a single coil with dual outputs. That changed the coils all together. I went with a Dynatek coil for a Harley because I could buy them individually and not waste a coil.



The coil used the original bracket modifiied and relocated where the reserve lighting relay was. Now both tanks can be fit without interfering with the coils and it is protected from the elements.

On to the muffler:

I finished welding the 2 into 1 header that was reconfigured from the old MAC that came on the bike. That was a lot of fun welding the pieces together at the bends where the metal was stretched to begin with. After that was sealed up and test fit I still did not have a muffler to put on when another one of my buddies donated an aluminum can muffler from one of his projects.



The bracket would not work, the pipe diameter was too large and the bend angle was wrong, but it was free and I think it will look good intalled. It should work well on the 650 too. I think it was off of an SRX600 single, but I'm not sure.



I had some straight pipe that was just larger than the MAC single pipe so it was a pretty easy swap with the original muffler inlet.

















The bracket still needs to be positioned, but all the clearences work. Iwill need to put a turn back on the muffler tip to get the exhaust to the rear, but it is aluminum and I cannot weld that. There are a couple of buddies who can though.

Rear Fender:

The rear fender has had me puzzeled for quite a while now. Originally it was going to be a standard motorcross fender with a small LED brakelight, but it did not really fit with the XS rear loop. Also, there was still a problem of the license plate. Today I decided to through a bit of kawi into this hybrid and adapt the rear frame section from a defunked 1974 F11 with a bent frame.



It will be an obvious Kawasaki duct bill on a Yamaha, but I really like those, it leaves plenty of tire clearance and I can get a bigger taillight further back on the bike. It also lends itself to tuck the license plate up it and give me a bit more fender.

The XS rear loop woul have to come off.





With the mono shock there is no need for the upper shock mounts, but I still need some strength there to support the back of the seat and the taillight, license plate, etc. The F11 tubing was about 0.020" too big to fit inside the XS tubing so I spent the next 45 minutes with a grinder and 120 grit flapper wheel trying to fit them together.

I did get them to fit so there would be about 1 1/2" of lug into the XS frame. There is also a small triangular support that I used from the F11 frame that should give plenty of weight bearing support.







It is just held in by the lugs right now. It still needs to be set in straight and welded in place. I mis-judged the angle on the gusset so it will take some work to get that fit prior to welding, but I'm pretty happy with it so far.

Other items that got done were adding the steering stop so it works with both tanks and adding gussets to the new foot pegs.
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