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Mad Sconnie
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2,602 Posts
Discussion Starter · #1 ·
Thought I'd finally post this up because I just got another large piece of the puzzle today. It's going to be a fairly slow build because of the mass amount of time I spend at work, in class, large amount of homework and an online class.

Picked this 1989 FZR 600 roller with title from Craig (CK 187) for dirt cheap and have been trying to come up with good project for it. Has pretty much all the FZR parts that I need for this build, plus some. Already started selling some of the parts I don't need to help keep the cost down. A few parts I don't have I am picking up from Chris (LRC131) from his FZR build over the winter.



After a bit of searching, I decided on which engine I would really like to put in the frame. I decided on a XS650 engine. Those have always been one of my favorite classic engine and have always wanted to use one in a build. Plus, they are just great looking engines.

I spent a lot of time on Craigslist, forums, ebay....... to try to find an engine for a decent price, but no luck. On a whim, I decided to ask my buddy Jack if happened to have one or knew anyone who had one. That's how I came across this.



It's a 1977 XS650. Jack said I now have about 80-85% of the complete bike in my possession. Should be everything I need from a XS for this build. He just dropped off the engine and this heap of XS parts this morning.


After a few conversations with Jack, and some research, I found out that this happens to be the engine that Ben (Ratfighter) had in his XS Interceptor hybrid. Guess this engine is lucky and will be going into a second hybrid bike in it's life. I started talking to Ben about the engine, and how much of a beast it really is. Ben suspects that this engine has some work done to is, but doesn't know for sure. I'm going to start tearing it down fairly soon to clean it up and replace seals and gaskets, so I should know what is done to it pretty soon.

Another pleasant surprise that came with the bike. A set of bigger Mikuni carbs that have been modded and tuned for this engine. Ben said that when he got these carbs tuned correctly, this bike pulled like a train. Can't wait to get it going.



Sound like a fun build anyone?:rock:
 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #3 ·

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Custom bikeporn addict.
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1,241 Posts
I happen to have an FZR frame in the basement. I found that a CBR1000RR tail, like 04ish almost fits perfectly on that bike. Like the rear seat almost fits right in too. Just some food for thought :D

Bob
 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #6 ·
I happen to have an FZR frame in the basement. I found that a CBR1000RR tail, like 04ish almost fits perfectly on that bike. Like the rear seat almost fits right in too. Just some food for thought :D

Bob
Thanks. I don't think I'm going to use a tail like that though. A little too much plastic for what I want for this bike. I'm going to try to keep it as minimalistic as possible.
 

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breaking stuff since 1978
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1,530 Posts
this should be interesting to watch. are you going for a modern fighter look or somthing a little more period with the motor??

what are you doing with the XS tanks??
 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #8 ·
IM doing something very similar. Its just an aluminum yamaha frame, same motor though.
I would love to put this engine in an aluminum frame. I am thinking about swapping on an aluminum swingarm and bracing it. I have to bother Craig if I want to do some welding on aluminum though. I generally bring stuff over to Chris's house to weld, but I can't do aluminum with his welder.
 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #9 ·
this should be interesting to watch. are you going for a modern fighter look or somthing a little more period with the motor??

what are you doing with the XS tanks??
Well, fighter style with some cafe inspirations. One of the major cafe aspects I'm planning on doing is swapping in a permanent magnet stator and running kick start only with no battery.

Selling the XS tanks. Interested? I haven't actually opened them up yet, but I was told that they are clean on the inside.
 

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fighter'n the good fight
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1,092 Posts
IM doing something very similar. Its just an aluminum yamaha frame, same motor though.
wtf? wheres the thread for that.


nice project btw. ill be watching this one
 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #15 ·
Had a little bit of time to work between school and work today. Was able to get the engine down to the camshaft. Don't have any time right now to take it down any further, but it's a pretty decent start for only working on it for 20 minutes. :party-smiley:


 

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Mad Sconnie
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2,602 Posts
Discussion Starter · #16 ·
Had some more time today to work on the getting the XS engine torn down. I was able to get the head and cylinders off.

Didn't have a cam chain breaker, and wasn't able to get enough slack in the chain even after I took off the cam chain bearings. So, I found the master link, ground down the pins and the master link just fell out. I'm planning on getting a new cam chain anyways when I rebuild it.


Once I had the cam chain and and cam shaft out of the way, I was able to get the rest of the head off the engine.


Then it was just a couple hits with a rubber mallet and the cylinders pulled right off. I noticed that the base gasket seemed to be cracked near the back of the cylinders, so I'm guessing that's where the oil that you see seeping from the back of the cylinders came from.


Just a picture of the head and cylinders off. These will get an extensive cleaning before the engine gets rebuild (possibly baking soda blasted)


The cylinder sleeves look to be in great condition, no rust, pits or major grooves.


So that's as far as I got today. I'm going to be ordering a complete gasket and seal kit soon and start cleaning the engine (possibly a little paint).
 

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UnicycleMode
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7,580 Posts
The cylinder sleeves look to be in great condition, no rust, pits or major grooves.
When I pulled it out of XS Interceptor I put a little 20w50 down the cylinders and used a cotton swab covered in oil on the end of a flexible grabber tool to coat as much as I could of the inside so it could survive sitting in the corner of the garage until somebody wanted it. ;)


Sub'd. This is looking like it's going to be a hell of a good build! :thumbsup:
 

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Fast ZX-12R
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17,522 Posts
I'll be watching this one too.
 
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