This 1978 build was begun who-knows-when by a long-forgotten owner in Kansas. A painter by trade, he did all the welding using off-the-shelf parts, and then powder-coated everything. And, a good job he did, with some nice welded customizations and solid paint work, especially the double gold pinstripe throughout.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-2.jpg)
And then the bike languished. Who knows what misfortunes befell the original builder?
Some 25 years later, the roller-with-an-engine was purchased for a song and moved to Texas. Owner #2 tried to finish the bike out, and pretty much ruined everything he touched. Realizing that he was in way over his head, he sold the bike to me.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-3.jpg)
Finishing the bike consisted of correcting owner #2’s mistakes and replacing his ill-advised appointments. And, adding ignition, charging, lighting, wiring, brakes, and all the trimmings, while trying to keep the bike true to the original owner’s vision. I think it has a cool old-school vibe that underscores its 25-year old roots.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-4.jpg)
That’s the short and sweet story of this bike.
One of the worst problems that I encountered was a mistake made by the original owner/welder. He placed the fake oil bag-electronics box too low, so that it was dangerously close to the chain. Owner #2 attempted to address this by adding an awful chain guide that he attached to the left-side down-tube with a big, ugly hoseshoe bolt.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-5.jpg)
After removing that mess, my solution was to add a Delrin rub block for the chain to the bottom of the electronics box, and to add a chain tensioner to keep chain flop to a minimum.
Another sore spot was the seat. As I got it, the bike had a god-awful seat mounted in a god-awful manner. It took a bit of work to get a nicer seat to cooperate with the existing mis-placed seat bungs.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-6.jpg)
A goal of mine was to see how little money I could spend, while still maintaining meticulous attention to detail. The only equipment on the bike that I could I tolerate keeping were the handlebars and the handlebar levers. Not the greatest levers, but they don’t look too bad, and they work okay. The rear brake master cylinder is a cheap universal eBay find. I also found a reservoir for the rear M/C that exactly matches the existing front M/C. I made custom brake lines front and rear – the rear line which precisely hugs the frame came out especially nice. The front line is held to the bottom triple with a trick little modified cable clamp as shown in pic #6
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-7.jpg)
Wiring was kept to an absolute minimum. There is a key switch on the left-side of the electronics box. On the right side of the box I mounted a momentary-contact push button for the horn, and a LO/OFF/HI toggle switch for the headlight. That pretty much covers the electrics. The engine is kick-only, as received. And, completely street-legal.
![](https://xs650chopper.com/wp-content/uploads/2021/01/25year-xs650-build-8.jpg)
I acquired those sweet grips in a trade some 10 years ago. They look like vintage bicycle grips, but they’re sized for a motorcycle. I’ve tried, but have never been able to source them. Just glad that I finally found a good use for them.
Owner #2 sold the bike to me for what he paid. I’d reveal how little I have in the build altogether, but I’m afraid of the push-back I’d receive when the time comes for me to sell it…
Submitted by William Melstrom