[4]

Yamaha XS650 16" to 19" rear wheel conversion

[3]
[10] Like what you see?
Click here to donate to this forum and upgrade your account!

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#1
I am starting a new winter project and picked up a very tired 78 XS650 special as the base for it. I'm going the 19" rear wheel route so I bought a 19" front wheel from another Yamaha. I measured the dimensions of the original 16" wheel and used them for dimensions to machine some spacers so the sprocket and brake rotor would be in the stock location in the swingarm when the wheel is centered. I bought a sprocket blank and machined the center hole and bolt hole locations to match the original brake rotor mounting surface on one side of the wheel. I bought a 4.5" chunk of aluminum from the chop bin at the local metal supplier and turned a portion of it to 4.100 which will be the finished OD of the spacers.

P9170223_zpsfd210903.jpg

P9200252_zps2207e3b9.jpg

Then I cut those slabs off in my band saw and trued them up on the lathe.

This is the brake rotor side.

P9190251_zps99c7ca97.jpg

P9190250_zpsbb57e568.jpg

P9190249_zps9d02c58b.jpg

P9190246_zps06c263a7.jpg

I used 12mm dowel pins inserted in the teeth of the sprocket so I could mount it on center in the lathe and super spacer chucks. That worked very well.

P9200255_zpsbe33bf47.jpg

P9200258_zpsa33373c4.jpg

Here's the sprocket I made next to the factory one. I used gunsmith's cold blue to cover the exposed steel area after machining.

P9210267_zps5e2f07b5.jpg

Here is the sprockert side spacer. I machined a pocket for an extra wheel bearing in the sprocket holder to help deal with the extra load on that side of the wheel.

P9200264_zpsf5cd108c.jpg

P9210272_zps2ed60c5a.jpg

P9210273_zps9262fcdf.jpg

P9210277_zps4fd17921.jpg

I machined a spacer to go between the two wheel bearings and another to go between the sprocket holder bearing and the left wheel bearing. I heated the sprocket holder up to 175 degrees with my heat gun and the bearing dropped right in

P9230296_zps2fcbd04a.jpg

P9230298_zps63d10753.jpg

P9230303_zpsb80875d3.jpg

Here's the assembled wheel ready to be mocked up in the swing arm.

P9240324_zpsff7d615e.jpg

P9240326_zpsff7c9a87.jpg

I clamped a lenght of 1/2" square aluminum shaft to the front sprocket to align the rear sprocket and measured and machined the outer bearing spacers from stainless.

P9240329_zps330b15fe.jpg

P9270335_zps0f5b5e98.jpg

P9270337_zps03b3190c.jpg

I mounted the front wheel on the forks and shecked the wheel alignment with 2 lengths of straight lumber and it turned out spot on.

P9270338_zps8fd65fef.jpg

P9270342_zps4747c7ac.jpg

P9270343_zpsfca936a2.jpg

Now that this part is done I will strip the entire bike down for re-build.

John
 

Attachments

SG51Buss

Active User
Registered
Joined
May 20, 2014
Messages
191
Likes
9
#2
Hey, Johnnyc14!
This is TwoManyXS1Bs from the 'other' forum.
Joined-up here not long ago. There's several others of us on here, too.
Your project is really lookin' good!
 

drs23

Active User
Registered
Joined
Jun 18, 2013
Messages
702
Likes
5
#3
Hey, Johnnyc14!
This is TwoManyXS1Bs from the 'other' forum.
Joined-up here not long ago. There's several others of us on here, too.
Your project is really lookin' good!
Fantastic job! Love it! Please keep us updated. I love a good bike build!
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#4
Thanks guys, old motorcycles and machine work go together like peas and carrots. It's cool to be able to make your own parts for this old stuff we work on. Steve, I like your clutch pushrods idea, I'll be making one of those at some point.
 

woodtickgreg

Active User
H-M Supporter - Gold Member ($25)
Joined
Jun 22, 2012
Messages
1,394
Likes
556
#5
Very cool, I love watching builds like these, please do post more as you go along. Aluminum is so fun to machine.
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#6
The used 19 inch wheel I bought came with 2 slotted 300mm front brake rotors. The original single front 300mm rotor and the rear 270mm rotor are not slotted. I plan to use dual front brake rotors and they will be the slotted ones so I decided to match the slot pattern from the front rotors on the rear one. I mocked up the first slot and spot drilled the center and both ends of the slot to get locations on the DRO. With the rotor mounted in an extra hub I made and in my Vertex super spacer I copied the location at 60 degree spacing around the rotor and drilled all the holes to 8mm the slotted them with a 1/4" end mill. The stainless rotors are pretty hard so it was slow going but turned out well. After the slotting I mounted it in the lathe and use 320 grit sand paper to polish it up a bit.

P9280352_zps86055ccc.jpg

P9280351_zps9ba00e15.jpg

P9280353_zps781ae06c.jpg

P9280355_zps4444e747.jpg

P9280356_zps5afd4e0a.jpg

P9280359_zps7a445667.jpg

John
 

Attachments

woodtickgreg

Active User
H-M Supporter - Gold Member ($25)
Joined
Jun 22, 2012
Messages
1,394
Likes
556
#7
Pretty cool, I am enjoying this.........
 

Davefirestorm

Swarf
Registered
Joined
Jan 6, 2015
Messages
3
Likes
0
#8
Very interesting reading,I have an XS650 I plan to convert to 19 inch rear wheel was going to do the machining at place of work but I no longer work and am without a lathe at moment.I was going to buy the conversion kit from Omars but will see if situation changes for me soon
 

zmotorsports

H-M Supporter - Gold Member
H-M Supporter - Gold Member ($25)
Joined
Mar 12, 2014
Messages
1,494
Likes
888
#9
Very nicely done Johnny. Sorry I missed this thread earlier.

The true level of workmanship in my opinion is to make it look like it rolled off the assembly line like that and not look like an afterthought. I think you nailed it.

Great job.
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#10
Thanks Mike. The Yamaha project has been put on hold for a while so I can get some other things done. I will get back to it soon.

John
 

bonneblktrk

Active User
Registered
Joined
Sep 28, 2011
Messages
46
Likes
15
#11
Side question from your cool machining projects-- How did you mount the chuck to your rotary table? I use mine alot but sometimes difficult clamping parts to it. A chuck would be very verstile.
 

zmotorsports

H-M Supporter - Gold Member
H-M Supporter - Gold Member ($25)
Joined
Mar 12, 2014
Messages
1,494
Likes
888
#12
Side question from your cool machining projects-- How did you mount the chuck to your rotary table? I use mine alot but sometimes difficult clamping parts to it. A chuck would be very verstile.
I just ordered an inexepensive 6" 3-jaw chuck and an 8" backing plate blank that I am going to drill to mount the vise to my 8" Vertex rotary table. I believe that is how most people mount theirs but I will let John answer on how he mounted his.
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#13
My rotary table is actually a Vertex "Super Spacer" model. It is sold with the 8"chuck already mounted. The down side is the mounting plate under the chuck is plain with no slots for clamping anything else. The 8" version I have is really too big for my small mill but the size comes in handy sometimes. It is a bit of a bear to move around as it weighs 175 lbs with the chuck.
 

bonneblktrk

Active User
Registered
Joined
Sep 28, 2011
Messages
46
Likes
15
#14
Thanks zmotorsports and johnnyc14 for the information.
 

zmotorsports

H-M Supporter - Gold Member
H-M Supporter - Gold Member ($25)
Joined
Mar 12, 2014
Messages
1,494
Likes
888
#15
My rotary table is actually a Vertex "Super Spacer" model. It is sold with the 8"chuck already mounted. The down side is the mounting plate under the chuck is plain with no slots for clamping anything else. The 8" version I have is really too big for my small mill but the size comes in handy sometimes. It is a bit of a bear to move around as it weighs 175 lbs with the chuck.
John, that is interesting the your Vertex doesn't have the slotted table. When I was looking for a rotary table about 8 or 10 years ago I saw some with a chuck mounted and some with the slots in the table and didn't know what the difference was. I purchased mine from a pawn shop and wanted it due to it having the slotted table and figured I could always mount a chuck to it down the road, especially for the deal I got on it.

I have not used my rotary table on my previous machine too awfully much because it was kind of a pain to set up the milling portion of the machine but I am starting to find many more projects on my new mill where I can use the rotary table. I just ordered a 3-jaw chuck and a blank 8" backing plate to mount it with so I am sure I will be using it more and more.

Again, awesome job on the bike John, looking forward to seeing more.
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#16
I got mine at a garage sale. It was pretty rough and rusty but I got it cheap. After taking it all apart and cleaning all the rust off I only had to replace 1 bearing on the hand-wheel spindle. It is smooth as glass now and has less than .001" runout so I very happy with it. The chuck alone is worth much more than I paid for it. This shows what it look like with the chuck removed.

P4121132_zps8502ae07.jpg

It's amazing how much crud was inside it when I got it but a little elbow grease and some Evapo-Rust and it look almost like new inside.

P4121114_zpse5512e3e.jpg


P4121117_zps95d33770.jpg
John
 

Attachments

zmotorsports

H-M Supporter - Gold Member
H-M Supporter - Gold Member ($25)
Joined
Mar 12, 2014
Messages
1,494
Likes
888
#17
Nice John. I do wish mine would loosen up a bit but with lack of use it is still quite tight. I guess I just need to start using it more.
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#18
Thanks Mike, where did you order the 8" backing plate from?
 

johnnyc14

Active User
Registered
Joined
Feb 17, 2013
Messages
274
Likes
647
#19
Forum member Adam Gibbons asked for dimensions for the wheel spacers I made for this sprocket. I had made a drawing when I made them so I will post it here in case anyone else would like the dimensions.

19inchwheelspacerdrawing_zps1f6ec48d.png
 

Attachments

[6]
[5] [7]
Top