XS650 Yamaha hardtail conversion with TC Bros rigid rear section. Step 1.

 We are pretty sure you know what a  Yamaha XS 650  looks like together, so we will start with everything striped off.  You don't need to remove the motor, but it makes it easier.  With our fabrication bench, we need the front end off also.

 Since this bike is going to be for Tom's long time girlfriend, I let him do all the grunt work.  Here he is making the first cut, removing the upper seat rails.  Cutting close to the backbone, so there will be less material to remove to make the backbone smooth.

 After doing all the cuts on the rear subframe, and doing the cuts on the lower frame rails, which need to be make .750" of an inch from a mount on the rail, you are ready to cut the seat post loose.  We cut them like in this picture to get the subframe out of the way, then you can cut the seat post allot closer to the lower motor mount.

 After that last cut you will know have two pieces.  Now is the time to make that cut on the seatpost, below the lower motor mount.

 You will notice that the frame sprung out of shape some what, but don't worry, when you bolt the motor back in, it will all re-align itself ( sometimes with a little help from a prybar).

 Now your ready to finish cleaning up the cuts, to get them ready to weld back together.  You will also be ahead if you finish grinding off all the remnants of the seat rails, so you won't have to try and do them once the hardtail kit is installed.

Here Tom is using a round file to deburr the lower rails to make sure the rear section goes on easier.

Be sure to stay tuned for Step 2, were we will install the hardtail kit.  We are a dealer for TC Bros, so if your in the market to buy a kit, or would like us to install it, be sure to contact us.

www.facebook.com/wisnercycles