XS650 cafe' project

I'm going to use a few bits left over from the SR500 on the '75 XS650. The SR headlight bracket will be cut up and welded to mount the headlight. This fixes a couple things in that it will lower the headlight, and also eliminates the stock headlight mounts that won't work with clip-ons (the clubmans are just for mock up). I'm also going to use the SR headlight.


Just test fitting here. Some small aftermarket gauges would be an easier fit, but I'd rather use the stock ones if I can get them to fit decently.


Getting the SR500 headlight and bracket to fit on the '75 XS650's 34mm front end, first thing was to shorten the bottom, saving the mounting tabs. The chrome on the outside of the ears is fine, but typical rust on the inside, so that will just get cleaned up and brushed with paint.


It will bolt on the same two places as the stock XS bottom headlight mount, getting the height and positioning just right here, since everything else is based off of this.


Welded up.


Next I removed the SR top mounting brackets, and tied the top together with flat stock. Then two pieces of 1/2" steel tubing from top to bottom, and some very thick tubing to mount the gauges. It will get painted black eventually. This is it after cleaning it by sandblasting.


The tubing just slides up the threads of bolts in the stock gauge mount in the top fork clamp, using some hose as bushings.


It drops the gauges about 3". The headlight is about as low as it can go maintaining plenty of clearance with the front fender at full suspension travel. The gauges are about 3/8" from the headlight at the closest point.