Yawn.... another bike build...

[jwhughes3]

suzuki?

they look like some suzuki ones? - deeper orange lens than the generic ones yamaha used... they look nice. i am curious too.

john

[crazy steve]

Ok, questions and comments...

Phil, the forks: yep, Yamaha missed the boat on the standard forks with the single bushing, but I think the main reason they put both bushings in the Special forks was because of the misalignment caused by those weird brakes. These you can align right and have 'normal' brakes, so it's probably a wash...

Russell, engine paint; I used this: http://www.eastwood.com/silver-argen...paint-set.html for the cases, FD, wheels. Not quite an exact color match for OEM but does have the right semi-gloss sheen, it's close enough for me, doesn't need a clearcoat, and doesn't mar easily. Not temp rated high enough for the barrels/head, but I don't see that as a problem (Yamaha used a different paint on the barrels/head too). It's a wheel paint, so should be pretty durable. The barrels/head I painted with a brush, using oil-based paint (in this case, XO Rust from True Value hardware). Don't scoff, I've done this before and it works good. You do have to cure it properly, but do that and it holds up well. Touch-up is easy...

Wiring... it helps that I'm a retired electrician, so figuring out circuits is easy for me. It's routing the harness that's the pain, so be sure and look in the FSM for that. Actually, the wiring on these isn't as intimidating as it seems; most parts will only plug in one way, and it's easy to check the harness while it's out for bad plugs, corrosion, damaged wires. Just take your time..

Turn signals.... c'mon, you guys need to think outside 'the box' more. After watching well-used Yamaha/Honda/Suzuki/etc signals go for more money on eBay for than I was willing to pay (particularly given their condition), I looked at what I usually look at when I want nice parts for cheap... Harley. Yep, these are HD turn signals, and I got all four in excellent shape for $30 including shipping. These are the '86-01 versions and was a 'set' (dual filiment front, single rear). Replacements are cheap/easy to find (you can buy complete new ones for under $15), and all sorts of custom lenses are available if you want. I modded these slightly to fit (drilled the 5/16" mounting holes out to 3/8"), but are otherwise stock. Sleeker looking than the usual Jap signals, I think they add a nice touch. There's all sorts of mounting hardware available, so I'm sure something could be found to fit these to a XS if you don't want to build your own parts...

[3Phase]

Hey, Steve, what did you do to cure that XO Rust, add a few cloves with a savory honey glaze then bake at 350* for six hours or what?

Your project looks absolutely amazing and that's sort of what I'm doing with my '79 Special. What the P.O. didn't outright destroy trying to "improve" his bike the years of sap from the bushes and the salt air in Lompoc finished....

[crazy steve]

Hey, Steve, what did you do to cure that XO Rust, add a few cloves with a savory honey glaze then bake at 350* for six hours or what?

The cure process is to start/warm the bike until you can start to smell the paint, then shut it off and let it cool. You don't want to see full temp right away. Do this multiple times until the smell starts to fade when it gets warm, then repeat, letting it get full warm and do the same thing. This usually takes 6-8 cycles to start, then another 4-6 at full warm. Once you get very little paint smell, it's cured and ready to go.

This gives you a 'baked enamal' finish, and it's very durable. I did this to my 650 XS2 and after six years it still looked great. It will chip, but all you have to do is dab a bit more paint on...

[3Phase]

Ah ha! thank you very much!

That seems a lot safer and easier than sticking the whole thing in the oven to cure the paint, then having to run for my life when it's discovered and/or the paint fumes launch the top of the stove through the ceiling.

[latexeses]

a savory honey glaze

You could use that "honey/grunion" glaze down there Scott. That salt air seasoned the rest!

[3Phase]

You could use that "honey/grunion" glaze down there Scott. That salt air seasoned the rest!

Grrr ... that's almost exactly what I'm trying to clean off of the '79 Special. It's not just corroded, it actually smells sort of sweet, fishy and salty. It's from all of the salt residue, the mold and the decaying seat, tires, brake fluid, oil, gas and grease. On the bright side all of the #%$^&* black widows are dead.

Again: Nice work there on your bike, Steve!

[crazy steve]

Wiring issues... Fixed!

A progress report..

Got the harness all in and other than some plug connections that drove me crazy for a bit and some non-pre-tested bad parts I had to replace, it went well and is 'proved' except for the stuff that needs the motor to run. And everything works! The hazard flashers, turns (including the auto shut-off), RLU, the works!
[IMG][/IMG]

I also installed one of TC's fuse panels, and after butchering the stock mounting until it was unusable trying to get the 'fit' I wanted, I broke down and built a new one...
[IMG][/IMG]
[IMG][/IMG]
... that gave me what I was after. I powdercoated it while I was also doing the correct centerstand which is now fitted. I also made a new headlight adjustment bracket for my Special headlight/ears-on-a-standard-tree combo...
[IMG][/IMG]
... out of some scrap stainless steel.

The things that gave me fits were the connector plugs, specifically the one for the turn canceller and the ones for the handlebar controls. I must have screwed with the turns for several hours, until the plug finally 'self-cleaned' from plugging/unplugging it, then they worked great. I did make an effort to clean it, but apparently not well enough; pretty hard to clean inside the female half.

It wasn't cleanliness on the control plugs though... After messing with several of those circuits, I finally determined that the connections were loose; after 'tweaking' the female sockets for a tighter grip, everything cleared up. Woo Hooo! I also got the brakes all filled/bled. I'd forgotten how spongy the front brakes on these feel with all those rubber lines... and no, I'm not buying braided lines; the next owner can make that decision.

Next up: carbs and bodywork/paint. I haven't really looked at the carbs yet. They were in a box when I got the bike (and still are...), I merely checked to see if the major parts were there and no broken posts. They still have the factory plugs on the idle mixture screws, so I'll see how badly those are frozen... wish me luck!

[bikerphil]

Looks awesome Steve. Man you have patience.

[crazy steve]

Phil, it's not so much patience as Norweigen stubborness to refuse to allow something to get the best of me; it will bend to my will!!

I was going to add that after doing this bike, there's definitely some things I'll change in the harness on the next one. I am going to spring for some Duestch connectors and banish those crummy OEM ones everywhere I can. I'm going to look at re-routing some if it too. One thing I partially addressed on this bike is I did 'bond' all the chassis ground points together by running a #12 between the three points, but I'd prefer to only have one main ground. I'm going to mod the frame slightly on the 'modder' for these things, and one item will be a more centrally-located ground. If Yamaha had spent a few more pennies on the negative battery cable, it could have been long enough to reach the engine ground...

[debauchery]

great job man shes looking really nice!!

[crazy steve]

First Flight!

Ok, finally got all the carb/charging system gremlins chased away and took it for it's 'first ride' in between the rain showers....

[IMG][/IMG]

Ran great, pulled cleanly from about 2K to redline, shifted good, I just need to 'bed' the new brake pads as the brakes are still a bit spongy. The tank is a 'temp' unit, I'll get busy on painting the tank I'm using along with the sidecovers. If the weather is decent tomorrow, I'll give it a bit more extended run and try to get all the crap burned out of the exhaust.

Woo Hoo!

[mjpxs11sh]

Yawn.........Looks Great! howd ya get the metal engine so shiny! mine could use some work. thanx now we all are aware of how much work WE need to do

[mjpxs11sh]

ooops. didnt proof read. i meant metal side covers. mine have spots and need some paste or sumthin! any advice. not even sure that my R/S metal is, but it wont shine and looks like aluminum

[3Phase]

Whoah! That looks really good, Steve, nice work!