Building a XS650 Scrambler

Discussion in 'Land of the Rising Sun: ADV Bikes from Japan' started by bbjsw10, Aug 12, 2009.

  1. bbjsw10

    bbjsw10 Adventurer

    Joined:
    Aug 3, 2009
    Oddometer:
    26
    Hey everyone, 1st post on here, long time lurker.

    I bought a 78 Yamaha XS650 Special about a month ago, planned on build a hard-tail bobber....... Well I have changed my mind, going dual-sport instead.

    My first bike ever was a 1986 CR80R and loved dirt bikes ever since. Now I can have a dirt-bike I can ride to work!!! :clap

    I bought it from a Yamaha technician that had it for 9 years, and recently rebuilt the motor on her. I added K&n's to it, and rejetted carb. I also put hi-po clutch plates and springs in her. I figured I may abuse it a little more than PO did, especially if I take it off-pavement. :evil

    Here a few pictures of what I have done so-far.

    First is I added some "motocross" handlebars from Jc Whitney, the only ones I could find that had that "vintage" look I was after.

    [​IMG]

    [​IMG]

    I also added a voltmeter, so I know if problems are going on. I don't want to be past u-turn time and not know it.

    [​IMG]

    I relocated the ignition to make room for the voltmeter.

    [​IMG]

    Drilled the front rotor after alot of thinking and planning it. I know some people are against the idea, but atleast I had assistance from my retired father that was a machinist for 40+ years.

    [​IMG]

    I have also began to go through and di-electric grease all electrical connections. I want to try to make them more water tite this way. I don't plan on crossing a bunch of water, but Murphy's law is always in play on a bike.

    Future plans:

    1. Install 2" over fork tubes and race-tech emulators.
    2. Change rear shock mounts to enable a 2" raise in back to match front. (I am 6' tall so I want seat a lil higher than it is now)
    3. 2 into 1 exhaust with a Supertrapp. I love the tuning opportunity of these and works a spark arrester as well.
    4. Track down some "standard" spoke wheels for this instead of the "special" mags it has.
    5. Possibly install a 4 Gal. "standard" tank, instead of my 2.9 gal. Added range.
    6. Paint (#1 Silver, #2 Blue) with some knee pads like the Trumpy's have.
    7. Knobby's of course.
    8. The list will grow, too many things in my head right now.

    That is all I can think of right at this time. I am getting knee surgery tomorrow so kinda, distracted right now.
    #1
  2. Dirty boy

    Dirty boy 120db piece of crap

    Joined:
    Jun 19, 2008
    Oddometer:
    47
    Location:
    Vancouver Island
    Sounds like you know what you want and I like what you are doing. Giver man have fun! Hope you have a quick recovery.
    DB
    #2
  3. JStory

    JStory Long timer

    Joined:
    Dec 21, 2004
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    3,126
    Location:
    Dixon, CA
    #3
  4. ODDSC

    ODDSC Adventurer

    Joined:
    Sep 19, 2006
    Oddometer:
    40
    Location:
    Corning, NY
    Keep us posted! I bought a '73 XS650 project bike, but haven't ripped into it yet. Still trying to figure out just what I want to do. I too was thinking bobber, but scrambler might be cool.
    #4
  5. Rich Dubbya

    Rich Dubbya Pimpadimpolis

    Joined:
    Feb 28, 2009
    Oddometer:
    244
    Location:
    NJ
    Between Omarsdtr and Mike's XS you have an ace in the hole when it comes to parts .
    #5
  6. bbjsw10

    bbjsw10 Adventurer

    Joined:
    Aug 3, 2009
    Oddometer:
    26
    Thanks guys, yeah I have looked at Omar's and actually talked to him about somethings on phone one day. Also Mikesxs.com is a God send for these bikes, spent $300 on odds and ends there already. About the exhaust I may just get some random sections of 1 1/2" pipe bent locally and weld up my own head pipes. I like making my own pieces.

    I ran across a picture of another XS650 scrambler that is kinda like I am going for.

    Here it is. Enjoy!!

    [​IMG]

    The main difference on mine is I will probably have some form of rack on the back, and a small fairing over the light (like some Triumph's have), mine will also sit a few inches higher.

    I am currently nursing my knee back to health. Just had surgery on it today at noon. I had a meniscus tear, fun, fun...:huh I am sitting with my friends, frozen peas on my knee at the moment. I am going to the garage tomorrow to sit on stool and atleast grease some more connections if nothing else.

    I also watched: Worlds fastest Indian, and One man's dream today. Both are awesome movies, both about kiwi's and their bike passion. That is all, going to bed now, I can take my last 2 percocet's for the day, finally and Good nite everyone.

    You will love your bike, and you should make a Scrambler. Much more versatile than a bobber. Plus you could always ride 2 up on one.
    #6
  7. dakdakdave

    dakdakdave an older,wiser noob!

    Joined:
    Apr 20, 2009
    Oddometer:
    396
    Location:
    Brisbane, Australia
    #7
  8. bbjsw10

    bbjsw10 Adventurer

    Joined:
    Aug 3, 2009
    Oddometer:
    26
    Thank you, that's absolutely stunning in my eyes. Now that is what I call a dirt bike. Thanks again, I saved that pic for sure.

    Wish I could visit there someday, the OZ that is.

    You wouldn't happen to have any more pictures of that bike would you? I love that thing.
    #8
  9. trustme

    trustme Long timer

    Joined:
    Jun 11, 2007
    Oddometer:
    1,103
    Location:
    Auckland , New Zealand
    I'm rather partial to the XS 650 as well, there are some pretty nice street trackers in ' olds cool ' let your finger do the walking in search mode.
    Good luck with your project
    #9
  10. RedShift42

    RedShift42 Some guy

    Joined:
    Feb 23, 2007
    Oddometer:
    321
    Location:
    the End of the Road-- Homer, AK
    Any updates on this, bbjsw10?
    #10
  11. SkaerE

    SkaerE Adventurer

    Joined:
    May 27, 2008
    Oddometer:
    55
    did you finish? i was thinkin of doing the same to a 74 i found. but i want to build a scrambler/great escape bike clone. :)

    just trying to figure out if i'll need a new tank... the stocker doenst look much like the scrambler's

    ideally i want soemthing close to these..... (one attached and my link to the other)

    http://www.advrider.com/forums/showthread.php?t=535169

    Attached Files:

    #11
  12. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    9,924
    Location:
    Yass, Australia
    G'Day guys, just found this post, here's an old 'Adventure' from oz,

    [​IMG]
    1975 XSB, usual modifications via MikeXS & 650Central,
    plus my own welding achievements :lol3
    [​IMG]

    This is my 'Touring' bike, for when 'Mrs Ghost' comes to a rally.
    Just love my XS650's
    #12
  13. MODNROD

    MODNROD Wheat and Sheep

    Joined:
    Feb 20, 2009
    Oddometer:
    2,637
    Location:
    Midwest, West Oz
    Good onya too mate!

    I just this afternoon finished welding up a single pipe and shortened Yoshi can to replace the two cans on my 640 LC4 SM. Blisters here and there, set fire to my hair with the grinder in the shed (as you do.....:lol2 ), but it feels DAMN good.
    Building the stuff is half the fun I reckon.
    #13
  14. Growl

    Growl Adventurer

    Joined:
    May 27, 2007
    Oddometer:
    92
    I appreciate your bikes. I wonder what gearing do you use. Also it seems you added additional lights... Have you upgraded the alternator?

    Thanks.
    #14
  15. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    9,924
    Location:
    Yass, Australia
    Gearing as follows;
    Normal - 18 / 34 - dirt touring [both bikes]
    Blacktop - 18 / 30 - with 16'' rear wheel, 18 / 32 - 18'' rear wheel
    Enduro [serious dirt] - 18 / 38-40 - with 18'' rear wheel.

    Alternator hasn't been changed yet, runs OK but the driving lights are only 55watts each with individual relays, soon to have brushless alternator from
    650Central [Mike Morse - California], avoid night riding where I am as the wildlife are dense in population.:gerg :mully :ricky
    #15
  16. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    9,924
    Location:
    Yass, Australia
    A few more photos, :lol3

    [​IMG]
    At 'Kowen Forest' Ride, April '09
    [​IMG][​IMG] A bloke as ugly as his bike, good fun!
    #16
  17. dungspreader

    dungspreader King of the Heap

    Joined:
    Jun 27, 2005
    Oddometer:
    451
    Location:
    In a field somewhere ,muttering .
    Bloody Great Pics there Ghost !:clap

    I've got a few XS 650s myself .
    One scrambler type as well as a roadie that's going to get a sidecar this spring .

    One question - what shocks do you use on the rear of your bikes for heavily laden touring and /or off tarmac riding ?

    All the Best .
    #17
  18. MikeMike

    MikeMike Long timer

    Joined:
    Feb 28, 2009
    Oddometer:
    4,150
    When Joe Minton used to write for Motorcyclist magazine and not about Harleys, he put together a nice 3 part spread on XS650 mods with Branch heads and Bub pipes. Not to mention some suspension work. You might be able to Google the articles, they also ran in a publication called "Great Bikes of the 70's" which was a Petersen Publishing one of back in 1981.
    #18
  19. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    9,924
    Location:
    Yass, Australia
    Just using 13" Progressive Spring [double spring] from MikesXS, :gerg
    Only problem I've had was one trip [two-up]into 'TTT' rally, :freaky

    but then I had too much weight past the axle and the road is fairly steep in places, [ears pop at least three times] it's 35km of firetrail with creek crossings, top rally though!:freaky :kumbaya
    Building a trailer to solve this problem:thumb :mully
    #19
  20. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    9,924
    Location:
    Yass, Australia
    Just keeping the thread active!
    Nov '09, North of Canberra,
    XSB650 'Adventure' & SH Special in rear :lol3

    [​IMG]
    #20