Need advice on XJ 650 Hardtail

Hey guys, first post here. I picked up my first 1981 XJ650 project. I am about ready to cut off the rear arm holding the shocks to do the swing arm hardtail conversion. I've doing alot of reading on here and looking through the photos that other members of posted as they went through there project but haven't really heard how they got to that point as far as where to cut what to watch out for and some problems the've encountered when putting the two new pieces of frame tubing from the back bone to the shock mounts on the swing arm. Any advice, pointers or just a general walk through on how you did it and what to watchout for when fabing up the rear section. I would appreciate any help here. Thanks in advance. (btw the tank was borrowed from a friend to see how it'd look with one of his tanks on it. It is not the one that is being used for the project)

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first off you need to cut the rear the rest of the way off at the swingarm pivot, throw the shocks in ur scrap pile. then you want to put a 3/16 or thicker brace or "stretcher" between where the framerails get narrow near the base of the tank from there run your round stock, preferably chromolly to the back end, or make a full cradle, easiest way is to run it to lower shock bolts if you are keeping the swingarm. if you want some pics pm me and i got tons from all kinds o xj and xv chops i have done just dont know how to put them up like you did

 

so how you makin out wih it? any updates?

 

gosh every time i click to see the bike in your sig i get the tinglies. love it.

 

I picked a welder from a buddy and rounded up the 1/2", 1/4", & 1/8" steel plate that i was going to use for tabs and brackets on the project. i'm all set up to cut the rear and start setting up the new frame tubes. Should be ready to knock that out in a few days. i'll post some photos once i have it all set up and completed. Ordered up the new bars for it the other day so should be seeing those shortly....well its Alaska so by shortly i mean 2-3 weeks...in the mean time i ground down and welded up the reflector mounts on the neck and welded up some holes/gaps to make the frame neck look a little nicer and cut off/smoothed out the fender mounts on the fork tubes.

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Quick question. I know the short VIN is stamped into the frame and is the same one that matches the number on the engine case. i want to remove that ugly ass sticker that is on the frame neck. Can i romove that with out any issue with the title or registration since its still on the neck and case? Most of it is missing anyways.

 

I would call your state's DMV. Each state seems to have different rules on this.

 

whats the rear tire that is on it now?? i kinda like the look of it!

 

no idea man, i'll take a look at the model of tire tonight, it almost looks exactly like the 16" rear tire that came stock on my '09 harley nightster, just has a slightly different tread pattern. the shape and design are almost identical.

so i went to the tags and title store here and renewed the registration and changed the title. No isssues so i've got new plates and everything is good to go. The lady there said that since the frame and the case are stamped with the VIN that is on the title, that removing the torn up sticker should be fine. I was reading through the forums it looks like the longer vins were introduced mid 1981 and they were over time changing to the longer vin #. so the factories where stamping the short vins into the frame and case and then the stickers where added later as they moved to a longer more in depth vin tag. so she said that if i was pulled over or the vin was run, the one on the frame neck would bring up my name.

i should be fitting and tacking the hardtail mock up this weekend. will try and get some more photos up early next week.

 

lookin good, as for the sticker........ check your title becausi removed my sticker and needed the whole vin for insurance and of course on the title and engine have a shortened version because of the redundant vin process that yamaha had in the 80s, if you remove it save a picture just in case.

looking forward to your update, love the welds ground smooth it makes for a sweet finish product

thanks mtnbikecrazy for the compliment, i really appreciate it

 

Got the motor pulled and the shocks removed. ready to rebuild the motor. Buying a new gasket kit and have the haynes manual to start tearing into her. Fingers crossed. Gonna be setting up the hardtail section here within the next week ar so when i get some time.



Was able to fab a piece of metal into the efi hole in the peanut tank. removed a portion of the tank support and drilled the mounting hole for the new petcock.

 

Getting ready to do the frame tubes this weekend. Found the thread on Crath's bike so have some pretty good ideas moving forward. maybe removing the rear tire to do the welds that he did to the swing arm.

 

Worked on the tank this weekend. Got the fuel bung welded in and polished out the tank. Going to skim coat and smooth with some filler.

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Just out of curiosity. How are you planning to run the fuel valve through the back bone?

Ghost

 

The frame is a 1-2 set up. the petcock is going to drop down behind the single tube in between the double and fit in between the two middle pod filters. and with the angle of the tank and the location of the petcock, this is going to give me the most fuel out of the tank.

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