XS650/Velorex Project under way

[ngthomas]

Howdy,

I finally got started on me project to rebuild and improve my XS650D / Velorex Sidecar outfit. I had posted about this project a couple of months ago but work and all has just overwhelmed me till now.

I have a new (to me) bottom end from a '79 coming so I can use the Mikes overdrive fifth gear. I also have the 750cc big fin big bore kit on the way. I plan to go with the Mikes performance cam but other than polishing the ports do not plan to do any other head work.

I will also install an electronic ignition. Any recommendations? Are there any to avoid?

Same for carbs. I am unsure if I should stick with stock carbs or get a new set. The ones on the bike have been sitting for 15 years so would need a complete rebuild but Mikes XS offers some Dellortos and other carbs as well. Any recommendations as to what works best? Any that I should avoid?

I have found a wheel builder who will lace up 15 x 4" automotive rims to my hubs so I can use 135x15 car tires all around on the rig. I got the wheels disassembled but still need to knock out the wheel bearings and clean them up before shipping them off this weekend or next.

I am designing the leading link front forks which I will fabricate myself and the adjustable toe-in for the sidecar wheel which I will also fabricate.

It is great to actually get started on this project. I will post pictures and designs as I get them if any one is interested.

Regards,

Nelson

[ngthomas]

Howdy,

Here is an updte on the project so far.

The wheel builder has the hubs and is putting the wheels together.

I have also commissioned a 2-into-1 header to go to a single muffler on the left side of the bike. This will move the sound source a bit farther from the sidecar passenger as well as avoiding the interference problems with the sidecar mounts on the right.

I received the '79 bottom end from California and the Mikes XS 750cc big fin big bore kit on the 17th so now I am getting things set up in the shop to begine dissassembling both engines. The 'new' bottom end looks to be in pretty good shape but will get a thourough inspection as it comes apart and anything suspect will get replaced.

I have been talking to Jay at DMC Sidecars and may have him build a leading link rather than doing it myself. Still have not made a final decision on this.

I will probably use the stock BS38 CV carbs. After 15 years of storage the are in dire need of a total rebuild.

I have decided on a chrome on black color scheme so I am looking for lots of chrome goodies and have found a chromer in the Portland, Oregon area that comes higly recommended by some of the car guys where I work. Fortunately we have a good powder coater here in town so once every thing is fitted up, put together and tested, the machine will get dissassembled again and all the black parts will go off to the powder coater. The wheels I am having built will come back with the rims and hubs opowder coated black and the spokes bright stainless steel. Other parts such as the drum brake housing on the rear and the wheel cover on the Velorex wheel will be polished or chrome plated.

Fortunately for me my wife is a tolerant woman and if she ever discovers what I am spending on this project I am sure I will survive... :-O

[ngthomas]

Howdy,

I have been taking things apart and ordering new goodies. All three hubs are in New Zealand with Gary at Vintage Rims. I hope to get those back soon. I have been talking to Jay at DMC Sidecars here in Washington and may have him build the leading link.

I have been looking into rephased engines as several of you have suggested this mod. The more I read, the more I am inclined to either rephase the crank or have someone such as Hughs Handbuilt do it. I plan to put a 220 watt permanent magnet alternator on the bike and had been planning on using one of Pamco Petes ignitions so I was pleased to see that a version is available for the rephased engines. I will go with the 277 degree rephase as that looks to be the most bang for the buck.

Hugh says he TIG welds the pressed joints on the crank. Is this a problem as far as replacing the connecting rods? I have not had to take the rods off the crank so I don't know if the welded crank would prevent this or not. Maybe the rods can be removed without the need to split the crank? Can anyone enlighten me on this.

Thanks,

Nelson

[XS Rod]

Hugh isn't the only one that welds the journals to the cheeks... My opinion is that the crank is fairly indestructible once thats done. Would it pose a problem on a future rebuild... dunno might. But I'm not rephased and there is a spare crank on my shelf.

[650leo]

The only way to replace the rods is to split the crank. So if you want new rods, put them on before the welding.

[ngthomas]

Howdy All,

I finally got my wheels back from the builder. I have pressed in the new bearings and seals and shoe horned the tires on. Since I want to run two discs up front I may run into a problem with the inner tube valve placement. Since these are car type wheels using car type inner tubes, the valve stem comes out one side. It looks like it will interfere with the caliper on that side. If need be I will block off the valve stem hole and drill a new one on the center line, then use a 140 x 15 motorcycle tube with the valve stem on the centerline.

Of greater concern is just getting the calipers on the discs ( or the discs into the calipers. The 15" rims do not leave much space. I may have to loosen up the bolts holding the disc on and pull the disc away from the wheel enought to gt the calipers on then tighten up the disc and calipers. Or I may have to find a more compact set of calipers. There is always something like this to make the project interesting. I am using a set of smaller diameter discs off of an XS750 and still just can't quite get the calipers over the disc. The stock diameter discs would never have worked...

I have everything off the frame and the engine out. The new wheels and rear shocks are on the bike, so tomorrow I will be driving over to Enumclaw, WA to drop off the bike with Dauntless Motorcycles to have a leading link built. I have taken too long to get to this point and his work load has picked up so I will have a fairly long lead time to get it back. In the interim I am going to start in on the engine. I have decided to go ahead and get it rephased 277 degrees as well as installing the big fin 750cc big bore kit.

So that is where I am at. I am disparing of having it finished this year but plan to do this project right rather than try and get it done fast.

Nelson

[grizld1]

Re. brakes and clearance: Remove the piston bodies and pads from the caliper assemblies, mount the wheel, then reinstall piston bodies and pads.

[ngthomas]

Howdy,

Time for an update on the project. Other aspects of my life keep getting in the way but I am back to making headway.

I have both my engines disassembled (the engine in the bike may have been a 75 rather than a 77. The frame and engine numbers don't match and I don't recall what year the donor bike was). The engine cases and transmission I will use are from a 79 bottom end I picked up so I can install a Mikes overdrive 5th. I can then play with the sprockets and get fifth gear to be the same as stock and the other 4 gears to be a bit lower which is good with a sidecar.

I am still awaiting my leading link. The builder contacted me and said the lower triple clamp was bent. It was one I picked up on ebay to replace my existing triple clamp because the existing upper triple clamp had been modified to reduce the trail for sidecar use. Since the original lower triple clamp was unmodified I dropped it in a USPS flat rate box and sent to him last week. I am hoping it is good or I will need to find a new triple clamp.

Am am still trying to decide which crank shaft to use. I think I will use the one that was in the bike as I know its history. I will be sending it off to Hughs Handbuilt along with the cam for re-phasing. Since I have a 20 ton press, I think I will go ahead and try disassembling the crank and reassembling it rephased to 277 degrees just for the fun of it... I plan to use the one re-phased by an experienced builder (Hugh) in the bike.

I have also moved my Velorex 562 into the shop and started taking it apart. I plan to put an electric tilt mechanism on it to allow adjusting the bikes lean out for existing conditions (with a side car this is a real advantage as without it the outfit is rigged for one set of road and weight conditions and change from these conditions adversly impacts handling).

I will update after I get my frame and leading link back.

Regards,

Nelson