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Discussion Starter · #21 ·
Rear end.
The hub on the TX was in pretty poor shape, so I mounted it on the lathe, trued up the flanges, removed the casting bridges between the fins, trued them up then polished the hub and brake backing plate. The rims were badly scored from tyre levers and oxidisation, so I ground the edges of the rims down as much as I could then polished it.. Then I spun up some stainless spacers and aluminium dust cover.
The brake anchor was a danged ugly thing, so I fabbed an ally one from 10mm ally, bending it to clear the tyre. Brake actuating rod wasn't in the best of condition, so I binned that and made a new one from 6mm stainless rod and threaded it both ends. To connect the rod to the brake foot lever I made a funny looking stainless thingy, no idea what they are called, but certainly a lot better than the original piece of rubbish. At the other end of the rod I spun up an adjuster nut and pivot, also from stainless.
 

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Nope, doesn't seem to be any interest in TX650s, so I'll move on.
looking for some buzz? spice it up a bit. start cutting and grinding. turn it into a cx500/cm400 or a virago. youll get interest. i jest but some of the others that post those bikes would really love it.
 

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Discussion Starter · #26 ·
I mocked up a right side exhaust then took it to an exhaust specialist who did mandrel bends and asked them to bend up four bends with the intention of welding them together to make two pipes. The guy at the shop told me he could bend the complete exhaust in one piece, including getting the twist correct. Naturally I said yes as it would save me a lot of work. Five weeks later they were ready, so, I picked them up, took them home and bolted them in place - dismal failure, the shop got the bottom bend wrong, so the pipes pointed downward to the ground. And, the distance between the bends was out by about 25mm, making the pipes sit too low.

Disappointed, I cut the pipe in the middle, between the two bends, removed 25mm and welded them back together with the right amount of twist. But, the pipe still pointed downward at an ugly angle. So, I cut a V piece out of the lower pipe about 75mm from the bend and bent the pipe up so it had a very slight upward angle. Once happy with the fit and angles I did the same with the second pipe.

Now, you'd think round exhaust pipe is round, wouldn't you? Nope, it aint, cut the pipe, twist the bits and put them back together and the bits have s teps where they meet. So, armed with a hammer, I beat the pipes until everything lined up, welded them together and got stuck into them with the B&D power file, then I set about making a couple of clamps and brackets.

The clamps were cut from 10mm ally, mounted in the lathe to bore the 42mm hole, then I measured up the two mounting studs and drilled two more holes in each clamp to match, then polished them. For the lower brackets, I bent up some 3mm steel in a half circle with Right angle bends at each bend and drilled four holes in each bracket. Next I bent up some 3mm ally in a half circle to match and drilled holes to match the steel brackets, then polished the ally covers.

To mount them to the frame I shaped some 3mm steel to the appropriate shape, drilled two holes to match the frame bracket and weld them to the steel half circles, then painted them in heat resistant paint. All in all, I'm happy with the final result, they match the bike well.

I did make one boo boo, made the pipes about 3mm too short between bends, the the right side pipe actually touched a protrusion on the right side cover. Easily fixed, I marked where it touched, removed the pipe and armed with a hammer and round bar, made a 3mm indent in the pipe.
 

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Really nice keep up the good work. Nice job on the frame if I remember correctly the frames used to have a lot of weld splatter standard. You may get inspiration from mikes xs or 650 Central for parts but you seem to be going well anyway.
 

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Discussion Starter · #28 · (Edited)
Yes, the frames are disgusting, I don't think the Japanese knew about welding or steel fabrication when they made these. Wherever possible I make my own parts.
 

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Discussion Starter · #29 ·
Pushed the starter button this afternoon and the TX roared into life, very loudly with those pipes. So, the single points cam works beautifully. PMA conversion works well as does the dual output coil, cable splitter, remote filter, cooler and ignition wiring. It's running a little lean at the moment due to the pods and exhaust, so I'll have to rejet before syncing. Very happy chappy.
 

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Discussion Starter · #30 ·
If you've set the float level in your carbs and want to check the actual fuel level , you'll need to access the float bowl. Most bike carbs have a plug on the bottom for emptying the fuel. If you have a spare plug, mount it in your lathe chuck and drill a suitable size hole through it. Don't have a lathe? Too easy mount the plug in the bench drill chuck and a drill underneath in a drill vice, or something similar and drill a hole through the plug. Don't have a bench drill? Too easy, mount the plug in your hand drill and the drill in a vice and drill through. Do not place a drill bit in the drill and drill through the plug, the hole will not go through centrally. If you want an accurate size hole, always use a pilot close to the finish size hole first, yes, even with very small holes. You'll need to either use a centre drill or centre pop the plug first. Then find a barb to plug in the hole, drill the through hole using the same method. For a leak proof join you'll need a barb10mm bigger than the hole. For example a 4.5 mm drill is actually somewhere around 4.34mm and drills a hole around 4.5mm or slightly smaller using pilot first, so you'll need a barb around .10mm bigger. You can turn it down on a lathe, or, turn to size using a drill and file.
 

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looking for some buzz? spice it up a bit. start cutting and grinding. turn it into a cx500/cm400 or a virago. youll get interest. i jest but some of the others that post those bikes would really love it.
as a long time xs1 and descendants fan I prefer them unmolested but cafe beats bobber if you must
 

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No bike is better stock. You have a stock bike? So does everyone else!
I disagree, I have a bone stock, 1989 GSXR 1100. I actually took off the aftermarket parts and sourced the original Suzuki ones because VERY FEW have one of these that is factory spec OEM.
 

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No bike is better stock. You have a stock bike? So does everyone else!
seen many here ( and everywhere else) turn good / stock rideable bikes into pieces of shit you or i wouldnt ride to the end of the street. and as far as todays prices go for used older bikes. whats going to fetch more cash? stock or somebodys dream of a “cafe racer”.
 

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A completely stock bike from a far gone era commands the highest value. To a collector, not to a rider.
 

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Discussion Starter · #39 ·
I disagree, I have a bone stock, 1989 GSXR 1100. I actually took off the aftermarket parts and sourced the original Suzuki ones because VERY FEW have one of these that is factory spec OEM.
Bully for you! Your point?
 

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Discussion Starter · #40 · (Edited)
seen many here ( and everywhere else) turn good / stock rideable bikes into pieces of shit you or i wouldnt ride to the end of the street. and as far as todays prices go for used older bikes. whats going to fetch more cash? stock or somebodys dream of a “cafe racer”.
If you're after money, the stock market is a good place! You're not going to make any 'cash' restoring bikes in your workshop.
 
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