The Mutt

So one of the cylinders on my 550 seca had low compression and my paint was just a quick flat black job I had done when I first got the mutt running so I could ride.

Now I've got the time, the space and the resources to give it a good overhaul.

I started with a not so complete bike way back in spring of 06. What I got was the engine in basically a rolling chassis and a mess of wires. The gas tank that was with hit was useless from sitting outside with no cap on it for years and a box full of parts... some were from the bike and some were from other various sources such as DSM's and junkyard pickings.

I got the bike from my room mate for all of $80 dollars that he owed me for bills. I made sure the engine turned over freely under it's own power before agreeing to it. It hadn't been running(obviously and had been sitting under a tarp for a couple of years.

How it sat more or less when I got it. The tank is the current tank, not the one I got with it.


Anywho on to some photos. Here is a shot of the first finish job I had.

I ended up finding a tank off of a 650 seca and modified the seat to fit.

Here is a shot of it next to my 77 enduro


The front end that came on the bike is off of a 650 turbo seca so I was able to do the swap for some R6 calipers. Added the dual Braided SS lines and the cafe bar end mirrors also a stock pipe from an R6 that my buddy had laying around.





I've done full gamut of carb cleaning and have always had a rough start, so the beginning of the year this year I decided it was time for a compression test, and sure enough, cylinder 4 was at 70 psi where as the rest of them were at 115-120 psi dry. They all increased dramatically with the wet test so def at least needed rings. Also turbo forks had blown air/oil seals, so away I went on the dismantle getting everything ready for a good overhaul.

Most of the parts I needed Chacal was more than happy to help with and as always did a great job of getting them to me. Might still have a few more things I need to get too.

On to some more pics


The shelf of parts


Engine torn down and ready to be package up till I get to it.


Frame getting ready for some cleaning up. A few brackets I no longer needed and a few things I need to add.

So that's how it sat a couple of weeks ago. More updates of the last few weeks to come.

 

Re: New paint job and engine Refurb on the Mutt

Looks like your going the right direction. Looks good to me.

I wish I had a seca rather than a maxim... and I love the front brake swap.

 

Re: New paint job and engine Refurb on the Mutt

Thanks man... Got a little time here so on to the next set of pictures.

The previous owner had bobbed the tail of the frame under the seat so I had originally just cut the fairing and glued it together by tucking the rear piece underneath the front piece and epoxying it together. I decided I wanted it to be smooth again so I went to town on the fiberglass and filler.

Here's a few of the steps.


Original length


Center piece out


Gooped up with filler ready for some sanding.

and photobucket just froze up so I'll be back later with more!

 

Re: New paint job and engine Refurb on the Mutt

i like the exhaust before the r6 one... but good luck on your adventure

 

Re: New paint job and engine Refurb on the Mutt

Thanks Schooter... I liked it too, but unfortunately I let a friend take it for a spin one day and he came back sans pipe. I went and looked on the street that he went down to no avail. luckily they all just slip on so i may find another one at some point.

 

Re: New paint job and engine Refurb on the Mutt

Allright laptop is back up and running and hopefully photobucket doesn't give me any more crap.

Here's a shot of the tank and tail primed sitting on the bike.



Basecoat on



Decals on


Pinstripe and some clearcoat



I need to redo the decal on the tail piece. It started to wrinkle after I started to spray the clear coat. I got the frame cleaned off down to metal last night so I will be priming that tonight.

Hoping to have to the painting done this week and get the engine taken care of this weekend. I'll keep the updates coming.

 

Re: New paint job and engine Refurb on the Mutt

<---jealous of your exhaust setup.

I love where you're going on this...nice!

 

Re: New paint job and engine Refurb on the Mutt

I'm really digging the paintjob. Can you tell me what setup you're using and where you got it and your paint? I want to get into doing my own as well. Right now I'm doing all the hard work of the prep, but just using rattle cans in the end and I want to do something that will look better and last longer.

 

Re: New paint job and engine Refurb on the Mutt

I got the paint from TCP Global and just using a small touch-up spray gun from harbor freight with my 2 hp 6 gal air compressor. It keeps up well enough for a bike but I wouldn't try and use it on anything larger. The white is all vinyl and the red is pinstriping paint. I used a self etching primer out of a spray can that I purchased from the Sherwin Williams automotive paint near my house, then just a rust-o-leum automotive primer, then the Color Coat(Base Coat) of TCP's Acrylic Enamel with medium reducer. I let that set-up and applied the vinyl then painted the pin stripe. When that was set-up enough I applied the clear coat. Still need to color sand with 1500 and 2000 to get out the dirt and orange peel and buff to really bring out the shine.

 

Re: New paint job and engine Refurb on the Mutt

I guess I'm taking a trip to HF then

Thanks

 

Re: New paint job and engine Refurb on the Mutt

yea this is the gun I'm using. Works well enough for my first time using a spray gun, just need to make sure you clean it really well between the color coat and the clear

http://www.harborfreight.com/touch-up-a ... 66871.html

 

Re: New paint job and engine Refurb on the Mutt

thanks man

 

Re: New paint job and engine Refurb on the Mutt

Love the paint job.. Mind if I steal that stripe for my project?

 

Re: New paint job and engine Refurb on the Mutt

Go for it. The white stripe was actually a large decal racing stripe from autozone that I just cut one side off of. Worked out quite well and it comes in a 24' roll so I had plenty in case I screwed up!

No work done last night. Went out and played some v-ball. Putting the color on the frame and small parts tonight. Start on cleaning and re-assembly of the engine tomorrow hopefully.

 

Re: New paint job and engine Refurb on the Mutt

are you just doing the frame black as well?

 

Re: New paint job and engine Refurb on the Mutt

I'm gonna spray mine.. If I can get the masking tape nice and straight it will look good.. The XJ900 tank is a wierd shape, and I've a bikini fairing to do as well, so a decal wouldn't be possible..

By the way, I like the tail shape you've got there.. Looks much nicer than the stepped cut up bit.

 

Re: New paint job and engine Refurb on the Mutt

yea, the frame is going to be black as well. I'm still trying to decide where to go with the engine accents. The valve cover will be red and the jugs and head will be black with the edge of the fins polished. and I'm thinking I'll be polishing the faces of the engine covers and whatnot with the rest of the engine in black and the starter motor polished. But my ideas are constantly changing so we will see.

 

Re: New paint job and engine Refurb on the Mutt

Thanks Swissjon, I'm really happy with the way things are turning out. The step-up that it was originally was really just out of inexperience and laziness. I've done some actual body work since then and decided it was time to do it right.

 

Re: New paint job and engine Refurb on the Mutt

LoL.. You gotta start somewhere.. I'm wayyyy behind you.

Where do you mount all the boring legal bits like licence plates after you've chopped it down?

 

Re: New paint job and engine Refurb on the Mutt

I haven't figured that one out yet. I had it under the rear tail light before with a custom bracket I made, I think I may make a bracket to hang it from one of the turn signal stalks or up from the rear axle. That's something I was going to work out once I have my signals and the bike is back together-ish.

 

Re: New paint job and engine Refurb on the Mutt

I like the "Up from the rear axle" idea.. You've cleaned up the tail nicely.. seems a real shame to spoil it..

There's always the option of keeping it tucked inside your jacket and saying "sorry officer, it just fell off" when you get pulled How do you feel about tickets?

 

Re: New paint job and engine Refurb on the Mutt

Yea that's more than likely the way I will go. Best part about making it yourself is you can change it if it doesn't turn out right.

 

Re: New paint job and engine Refurb on the Mutt

Make sure to tuck the clutch cable in where it belongs. Looks like your cable is about 3 feet too long.

 

Re: New paint job and engine Refurb on the Mutt

Yea, because of the clubman bars it is a little longer than it should be. In the first pic you see it in I hadn't routed it at all. I later had it routed along the frame rail as you can see in the pic of the front brakes. It could probably be 6-8" shorter and be ok. But it works fine the way it is. Someday I will find one that is a better length but I have other things to worry about at the moment.

Cleaned up the jugs today and got the valves pulled out of the head. Frame has a couple coats on it and then I ran out of paint so I'm waiting for more to finish that up. Going to clean the head up tomorrow and lap the valves and start working on re-assembling the engine.

No pics today.

 

Re: New paint job and engine Refurb on the Mutt

Haven't updated in a few days. started putting the engine back together, got all the side covers back on. Put the cylinders on only to realize I missed the base o-rings and as I was pulling them back off the gasket got caught on the stud in the front and tore. That's what I get for not paying attention.

I'm going to be finishin up the paint on the frame and all the small pieces tonight. then let that set-up over the weekend and I should be starting to put it back together on monday. That's when the real fun begins.

Here's a shot of the frame and the swingarm hanging up partially painted. Ran out of paint on friday and had to order more.

 

Re: New paint job and engine Refurb on the Mutt

Can't wait to see the final product. Looking awesome!

 

Re: New paint job and engine Refurb on the Mutt

Thanks shnuffy,

Started getting the frame together yesterday and got the engine painted and started cleaning off the ribs before I ran out of steam. Long weekend of partying.

Heres most of the painted goodies.


Here's the frame with the swingarm and triple tree on it. Used the roller bearing upgrade from Chacal on the swingarm. Went together great!


Here's the engine as it was at 10 last night. Still need to clean up the yics cover and going to add some red accent to the stator cover.

 

Re: New paint job and engine Refurb on the Mutt

Finished sanding the fins last night, got the cams back in and timing set up. Turns over smoothly. Also pulled the old rubber off of the rims. Painting the rims tonight and cleaning up the yics covers and the valve cover. Possibly putting the engine back in the frame tonight too.

 

Re: New paint job and engine Refurb on the Mutt

NICE!

 

Re: New paint job and engine Refurb on the Mutt

Got the engine in tonight... its coming together quicker and quicker.



Also got the rims painted and curing waiting for the rubber to be mounted. Thinking I'll be taking them somewhere to be mounted more for saving time than anything.

 

Re: New paint job and engine Refurb on the Mutt

Looks very awsome.
I know your already very proud of the work done and have inspired
many to take the plunge into custom bike building.

 

Re: New paint job and engine Refurb on the Mutt

Thanks Parts... I think I'll be dropping the rims off to have the tires mounted either tonight or tomorrow morning. Going to put the handlebars back together tonight and start on the wiring I think. Tomorrow the exhaust gets mocked up welded, painted and wrapped and a battery/electrics box gets made and painted. If all goes well should be running it by sunday at the latest hopefully.

 

Re: New paint job and engine Refurb on the Mutt

well it's coming along, got the new rubber mounted. Ended up doing it at home last night and this morning. Moving on to the exhaust and the battery/electrical box.

 

Re: New paint job and engine Refurb on the Mutt

Coming down to the wire for the trip this weekend. Should be firing it up tonight. Had a couple of housewarming parties this past weekend that slowed me down tremendously! Anywho, the battery box is done and ready to be installed. Header is welded and wrapped and will go on tonight. Carbs will go on tonight. Make sure all the bolts are torqued to spec. and see if she fires up. I'm going to have to put on the old ratty/broken turn signals till I get my new ones in. and I still need to make a mount for the license plate. But that shouldn't take too long.

Here's a few shots I took of it last night around 12:30.(These late nights and early mornings are killing me!)

 

Re: New paint job and engine Refurb on the Mutt

where did you get the wrap for the headers, how much did you need, and how much was it? That is one of my next purchases. Bike is looking good. good luck on the start up.

 

Re: New paint job and engine Refurb on the Mutt

I got it from corsportusa.com it was a decent price. I ordered a 50' roll of the 2" and have maybe 10' left. It's the dei brand that they carry.

 

Re: New paint job and engine Refurb on the Mutt

awesome.... I see it....black 2" x 50' roll for $33. Not bad. I'll order it tonight.

Thanks for the immediate response.

 

Re: New paint job and engine Refurb on the Mutt

Glad I could help.

 

Re: New paint job and engine Refurb on the Mutt

Electrical is all hooked up, exhaust is on. Still need to install the front brakes, turn signals, and license plate. and then put in the fluids and see if she'll fire up!

 

Re: New paint job and engine Refurb on the Mutt

Game... Count it. Got her running and took for a quick spin. The Speedo I have is junk so that will getting replaced soon. Still need to paint the license plate mount and add a light. Also waiting on the new turn signals









Let me know what you think. Personally... I LOVE IT!!!

 

Re: New paint job and engine Refurb on the Mutt

Nice looking bike. Did you paint over the exhaust wrap? When I did mine two years ago the DEI instructions suggested you paint it with their hi heat paint. I did and it held up well until I cut it off earlier this year to redo the exhaust.

Also you can use these for plate lights: http://www.customdynamics.com/illuminat ... _Tag_Bolts

I got a set for mine. Not wired up yet but I lit them up to see how bright they were and they look plenty bright enough. I got the ones with the red rear facing bulb as well.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

Thanks iwin... I didn't paint over it yet, wanted to burn all the crap off of them first and get them installed. I have some VHT flat black I will be spraying them with.

Those bolt lights look sweet, I will have to look into those when I get back from my trip.

I may also have to move my plate back up to under the tail light. One of my buddies is telling me it is illegal to have it there or something. Looking into it.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

yup going to have to move it. Needs to be placed horizontally apparently. Lame.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

That is pretty lame about the plate.

When you do paint them make sure you don't start the bike in a garage or close to a open window. The paint smokes like crazy and smells pretty bad when it's curing.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

Thanks for the heads up. I will be sure to avoid enclosed spaces. Probably just drive it down the road and smokescreen the neighborhood.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

The directions are on the can. It's like idle for 10 min shut it down and cool. Idle for 20 minutes, cool. run for 20 minutes cool. cured.

I don't know if it would make much difference in the curing to just run it for a nice hour long ride.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

The idea is to heat it up slowly.. If you just take it for a 1 hour run, the inside gets really hot, the outside of the paint stays at air temperature, the paint dries unevenly and cracks. Eventually it'll peel off.

You only need to do this once, and it's only the first 10 min and 20 min that's important.. 1/2 an hour out of your life to get it right.. In my book it's worth doing.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

I will more than likely do it that way swissjon. Need to get it tuned first. I think it's still running a little lean so I def do not want to idle it for too long.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

The wrap is part of that problem. The inside of the pipe stays hotter the exhaust flows faster. Or so I read.

 

Re: New paint job and engine Refurb on the Mutt - 99.99% done!

Thanks for the input.

The wrap, the 4-1 the pods... it all adds up to a tuning nightmare. I had it very close to in tune before the rebuild but that was with a cylinder that had low compression. At least as close as I could get with a cylinder with bad rings that is.

I have a couple different jet sizes to test out and the pilot screws are at the stock setting, I will be balancing and colortuning before I ride it any more. I just needed to take it for a ride to break the rings in a little.