Just another 650 ADV bike

Discussion in 'Old's Cool' started by SOS, Nov 22, 2012.

  1. PhiSig1071

    PhiSig1071 What's ******width?

    Joined:
    Apr 9, 2008
    Oddometer:
    2,573
    Location:
    Tucson, AZ
    Crazy. But entertaining. Carry on.
    #41
  2. bpeckm

    bpeckm Grin!

    Joined:
    Apr 2, 2008
    Oddometer:
    6,130
    Location:
    Road Island
    I think it was an auto supply store, used for door gasketing... it had a really sticky side to it (peel off the backing) and worked great. I think it helped distribute the load from the seat all along the subframe.....

    :evil
    #42
  3. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    Hard to find time to work on the 650, but I did get some of the mounts done.

    The upper motor mount had to be redone in order to fit the MX125 tank. The original mount was a funky 3 piece per side deal:huh Not sure why Yamaha did that, but here is the making of the new mounts.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    The other issues were the rear brake stay and the mounting for the muffler onto the frame. I originally had the brake stay mounted to one of the main bolts for the pivoting dogbone on the suspension linkage, but I was affraid it would fail after some fatigue. Also, it was getting pretting crowded in that section of the frame with the rear brake pivot, brake stay, suspension linkage mounts and then a muffler mount.

    In the end I was able to weld a single mount to the frame that would serve both as the brake stay mount on one side and the mounting point for the muffler on the other side. It took some planning to get the mounts to work while still being able to remove all the hardware (i.e. not welding in a frame piece so I couldn't take the suspension apart).

    Here is the muffler in roughly the position I wanted it in.

    [​IMG]

    And making a bracket to hold it there.

    [​IMG]

    And the 2 mounted together

    [​IMG]

    [​IMG]

    I think that is the last piece that I need the motor mounted in the frame for. There are a few odds and ends to work on, but I think it is time to tear everything down for final welding and then rebuilding everything. It's been a long time to get to this point and I'm glad to be moving on to another phase:D
    #43
  4. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    8,926
    Location:
    Yass, Australia
    Definately looking an interesting concept, can't wait to see the finished product! :clap
    Cheers
    Baza
    #44
  5. NortwestRider

    NortwestRider TRIPOD ADVENTURER !!

    Joined:
    May 25, 2008
    Oddometer:
    4,250
    Location:
    3.7 miles North of Hell...SEATTLE....
    Cool build !!.


    Sent from my iPhone using Tapatalk
    #45
  6. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    8,926
    Location:
    Yass, Australia
    Forgot all about this build, wonder where it's up to now? :clap
    Cheers
    Baza
    #46
  7. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    I finally got back to the xs650 adv bike. Hopefully on the road by spring.
    #47
  8. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    One of the reasons this project got put on the back burner was a piece I added to the back of the frame to support swing arm. On the YZ125 the swing arm mounted on the rear of the motor so I added a bracket on the frame of the XS to give the swing arm the same support. Unfortunately, when I welded it up it shrunk and the swing arm axle would barely fit. It took hours of honing to get the swing arm axle to fit again. But that is done and now I can move forward again.
    #48
  9. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    8,926
    Location:
    Yass, Australia
    Good to hear that it's still on the roll, hope it's coming together OK, always a few hiccups along the way :rofl
    Cheers
    Baza
    #49
  10. G54B

    G54B Adventurer

    Joined:
    Oct 29, 2013
    Oddometer:
    57
    Location:
    Gunningbland, NSW, Australia
    I'd be adding another muffler mount, maybe half to 3/4 of the way up the can, just so it's got a bit less chance for vibration to fatigue (and eventually crack) the lower mount you made up.

    Looks bloody good otherwise, colour me impressed:thumb
    #50
  11. orangebear

    orangebear Long timer

    Joined:
    Aug 12, 2010
    Oddometer:
    1,312
    Location:
    dumfrie scotland
    cool looking build are you going to add an angled end cap to the silencer to stop water going in to it when its parked out.?
    #51
  12. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    Yes. There will be an elbow that points back, both to keep the water out and to not warm my bum with the exhaust. Along with that I might be able to incorporate a mount at the elbow. That would make sure it would be well supported.

    Thanks for the hints. It will keep the rework down after it is on the road:ear
    #52
  13. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    There has been one part that is the keystone for the rear mono-shock suspension on this project. It is the lower wishbone connecting the lower shock, swing arm linkage and frame.The blue one is what I need, but that obviously will not hold up long.

    [​IMG]

    I had a buddy that was going to make it, but he is busy with his own work. Now I have a regular machine shop that makes plugs and pistons for us and they are going to make it for me. I wasn't sure they would want to do a one-off, but they agreed.

    [​IMG]

    Now that it is going off to be manufactured I needed to make sure there would be no surprises when I installed it, so some mock-up was in order. The swing arm needed new bearings and some clean up.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    This is the piece that I added to give the swing arm some lateral support since the YZ originally went around the motor.

    [​IMG]

    Once I had the shock installed without a spring I could cycle it and make sure all was good. The it was time to make it a roller again.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    I should be able to keep assembling it now, though there is a lot of cleaning and other work to do. The original motor is in pieces in my basement with some issues that need to be addressed. It will need at least 1 rod. Fortunately I have an earlier motor with good compression. It is a kick start only motor so I will not need to plug the electric starter. That will go in over the next few days.
    #53
  14. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    I got a call from the machine shop about my wishbone they are making. Looks like when the holes are compressed together as I need them the clevis for the lower shock bearing and the swing arm linkage arm mount want to share the same space:cry

    That could really put a hamper in my plans and all the work so far:jerko

    After talking with the machinist and a couple trips down there I think we have a solution. We are shrinking the outer clevis dimension about 1/8" on either side and increasing the support below the clevis to make up for thinning the joint at the bottom of the clevis. We are also raising the landing at the lower shock mount to increase the amount of material at the clevis joint. So far so good:D
    #54
  15. hunter_greyghost

    hunter_greyghost XS650 Allroads Traveller

    Joined:
    Sep 10, 2008
    Oddometer:
    8,926
    Location:
    Yass, Australia
    That is looking so sweet, :drif
    even though it'd be too tall for me to ride - well if I used a high gutter it'd be OK :lol3
    top job old son, keep the flow going!!! :freaky
    Cheers
    Baza
    #55
  16. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    There has been some progress, but time is limited. While the machine shop is making the wishbone for the rear suspension linkage I've been trying to prep the early XS2 motor. I am not sure of the history of that motor, but it had obviously been dropped or in a wreck at some point.

    [​IMG]

    [​IMG]

    [​IMG]

    It turns over with good compression so I thought I'd throw this in and get it going to test the bike. The original motor has issues that will need a full rebuild. The XS2 motor is ideal for this project because it has no electric starter so no need to plug the starter hole. It was missing the ignition and advance rod and associated points, advance mechanism, etc, but the ones from the 1979 motor are identical so out comes the simple green and tooth brushes :puke1

    After the clean up I set it in the frame and started attaching some of the parts. It had been a long while so I need to remember where I was and what still needed to be done.

    [​IMG]

    [​IMG]

    I ran through and set the cam chain and valve clearances.

    [​IMG]

    [​IMG]

    [​IMG]

    There were some studs that need to be replaced at the tappet covers and one I need to helicoil.

    [​IMG]

    [​IMG]

    [​IMG]

    After that I went to fit the stator / sprocket cover. That is when the woes began:cry

    The cover did not want to fit. I also noticed then that the cover was from a later bike as there are 2 holes on the bottom, that do not jive. That is not a big deal as it is not an oiled part, but this was a bit more concerning:eek1

    [​IMG]

    I should have seen it earlier, but when I got the motor this cover was not on it. The shift shaft looked like a failed pretzel. Fortunately I have a spare motor and they share the same part number so I have the part, now to get it out:huh

    Luckily there is no need to split the cases, but the clutch basket does need to move out of the way.

    [​IMG]

    As is usually the case it is really good luck that I needed to pull the clutch cover. I do not know if you can see in the picture, but one of the clutch spring screws was loose and backing out.

    [​IMG]

    That could have made a mess if it came out while running.

    At some point after I put the motor in the bike I installed the timing shaft from the 1979 in and installed the Pamco ignition.

    [​IMG]

    [​IMG]

    [​IMG]

    Tonight I'll pull the shift shaft from the 1979 motor (that is at home) so I can install it tomorrow. The next step is to start the new wiring harness. Maybe some time in the Spring it can get out for an initial road test:lol3
    #56
  17. _CJ

    _CJ Retrogrouch

    Joined:
    Dec 29, 2010
    Oddometer:
    1,805
    Location:
    The 719, Yo.
    Don't know if you have considered this, but CNC aluminum (what you're having made?) isn't even close in strength to forged aluminum (like that factory piece).

    There was a trend in the mountain bike industry where everyone with a CNC machine started popping out parts....crank arms, brakes, bottom brackets, stems, etc....then snap, snap, snap, there was a rash of broken parts and people getting hurt. Today, there are few if any CNC aluminum parts on the market.

    I'd be willing to wager that if the steel piece you have there were welded together, it would be infinitely more durable than a CNC'd chunk of aluminum.
    #57
  18. Cogswell

    Cogswell Spudly Adventurer

    Joined:
    Jan 3, 2005
    Oddometer:
    4,797
    Location:
    Riding with my pal Richard Cranium
    FWIW, I've had success straightening bent shift shafts with a press and some V-blocks.

    Good to see you making some progress on the build.:freaky


    Mike
    #58
  19. SOS

    SOS Ignorance is a gift

    Joined:
    Jan 15, 2008
    Oddometer:
    722
    Location:
    0hio
    Thanks. It will be nice to finally get this on the road.

    About the forged aluminum. I have never heard of an aluminum casting being know for it's strength, only that it is cheaper to produce. I will look into that though. Now that the machine shop has the drawing made up it will not be hard to get a steel one if I need it. The mock up is just pieces of aluminum bar pinned together, so that won't do.
    #59
  20. _CJ

    _CJ Retrogrouch

    Joined:
    Dec 29, 2010
    Oddometer:
    1,805
    Location:
    The 719, Yo.
    I would imagine that the shock link is a highly stressed piece, and needs to be able to take a lot of punishment, kind of like a crank arm on a mountain bike. I've personally snapped several CNC'd crank arms, but never one that was forged.

    .
    #60