Yamaha XS650 Cafe Racer: custom horn

Custom Horn Switch for the Yamaha XS650 Cafe Racer

Custom Horn Switch for the Yamaha XS650 Cafe Racer

It’s been a while since we posted any updates about Danny’s Yamaha XS650 Cafe Racer.  Danny has been hard at work…at work.  So that has left little time for getting the bike done.  But yesterday, the custom horn switch was completed, and the damn thing works like a charm…

The Yamaha XS650 Cafe Racer gets some bar style.

Having rid the Yamaha XS650 Cafe racer of the stock handlebar controls, Danny had decided to make his own custom horn switch.  A horn may be far down the list on most custom bikes, but given the chance to make something new out of aluminum, Danny was all over it!

Recessing the button into the body was a challenge...

Recessing the button into the body was a challenge…

The trick was to ensure that the button, recessed into the body, was not making contact with the wire which triggers the horn, until the desired moment when you get cut off by a taxi.  No one wants a horn blowing randomly, so care was taken to make a Lucite inner which isolated the contact points.  Fine measurements and some polishing left the piece looking and working right.

Of course, once the switch was done, and mounted on the Yamaha XS650 Cafe Racer, it seemed not to work.  A quick test of the horn itself revealed that the stock part had gasped it’s last honk, so the horn from the Honda HawkGT was tested and mounted instead.

The build turns to the carbs and exhaust, tweaking the final functionality of the bike.  Extra jets have been purchased, and despite the cold weather, it looks like this bike will see a wintry unveiling soon.  All’s working fine and dandy, and now Danny will have some safety to go with his custom bike…

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