XS650 enduro project

I've been working out some of the last details on the XS so I can tear it down and get started on the finish work. One thing was the seat latch.


The latch was right where the side cover is, so needed moved.


I cut the end of the latch off.


The solution, I welded it to the rear seat damper mount a couple inches back.


I then made a bracket to mount the latch lever.


I also got a new cover for the seat, so once I blast and paint the pan it'll be ready to upholster.


I'll be using a 5" TT500/TY250 headlight. I bought a 15-005 shell and 19-021 grill from The Vintage Spoke. These new parts were quite a bit less expensive than beat up used ones usually go for.


I bought a NOS Yamaha 434-84120-60-00 lens.


It was used on 6V bikes, but since it isn't a sealed beam I'll be able to fit a 12V bulb.


I got three used 195-84324-00-00 springs to mount the lens.


Coolest headlight ever.


To mount it I got some used TY250 ears. I'll probably blast these and paint them black.


The skid plate will be like the one on my '79 XS650, other than it won't need to be cut around the stock side stand, so I took it off to use as a template. I'm making it from the same stop sign.


I have a deck porch on my shop, and it works good for bending the aluminum to the needed shape.


Here it is after shaping and I'm fitting the front mounts. I bolt them to the skid plate and then trim them to fit the frame before welding.


Here it is so far. I've still got to finish mounting the skid plate, and modify the steering stops for the XT/TT500 front end. The seat cover is just sitting in place to see how it will look. The bike should be ready to break down next weekend.