1980 XJ Cafe Project (With Completed Pictures)

Re: 1980 XJ Cafe Project

Great job on the seat, can't wait to see the final pics.

 

Re: 1980 XJ Cafe Project

Thanks guys, I will be doing glamor shots once it is complete and has been through the paces for a few rides. So don't worry more motorcycle pron is on the way!

 

Re: 1980 XJ Cafe Project

Unless I missed it (very possible), any plans for rear fender? Pods sure don't like gettin' wet...

skillet

 

Re: 1980 XJ Cafe Project

Nope, you did not miss anything. I have yet to make one up and for now this will only be a fair weather bike. I am still working on how to fully seal off the electronics under the seat also. I know they would get wet some how if I did ride in the rain so for now I'm hoping I never get caught in the drizzle!!!

 

Re: 1980 XJ Cafe Project

Might be a bit late with this, but Helicoils aren't ideal for threads that see a lot of action. It could hold through many services so check it every time and use minimal torque. Not sure if these use an o-ring or washer to seal, o-ring would be preferable.

 

Re: 1980 XJ Cafe Project

Sorry Dudeman, I decided to go with the helicoil. I was going to use one of those steel insert things but the kit alone was over 100 bucks for the correct size. Got the local machine shop to do it for 40 buck in an afternoon.

So the bike was running very well up until the other day... So my girlfriend has been itching to ride this thing (yes she can ride, done a few track days) and i go to put her on it, she clicks it in gear, starts to let the clutch out and it dies. We try to start it in gear with the clutch pulled in and it tried to start but spinning a lot slower. I put it in neutral and it fires right up. Click first gear, try to take off and dies.... So I pulled the clutch in and tried to roll back to the driveway and it feels as though the clutch is dragging. I click to neutral and it rolls smooth...

What do you guys think? Clutch friction plates? I doubt the clutch has been changed in a long time, but it was working perfectly before...

What about the cable? I know its the original one, maybe its stretching and its not actually disengaging the clutch when its in gear and i pull the lever?

Those are about the only two things I can think of, what else do you guys have for me?

-Chris

 

Re: 1980 XJ Cafe Project

I had a problem with chain oil and road dirt making the safety switch beside the small engine sprocket under the cover cause the engine to cut out when riding. On my Seca it will not turn over in gear. May not be your fix but a good idea to keep that aarea nad the swith under the side stand clean and sealed with silicone just in case

 

Re: 1980 XJ Cafe Project

lol - aarea = area, nad = and swith = switch - not drinking honest lol

 

Re: 1980 XJ Cafe Project

Yeah, I'd say it's a good idea to keep your nads clean...

 

Re: 1980 XJ Cafe Project

So any updates?

 

Re: 1980 XJ Cafe Project

Yes, my nads are all sparkly 'n' sweet smelling thanks

Wondered if the sidestand switch was iffy on it, the original problem?

 

Re: 1980 XJ Cafe Project

VERY nice effort so far! Are you going to do anything to the tail-end of the 750 Seca tank to hide/use the side panel tab hole?

 

Re: 1980 XJ Cafe Project

wow. impressive man! cant believe you got those forks to work on these old ass bikes. nice touch wish i had your tools! haha

keep it up!

 

Re: 1980 XJ Cafe Project

battery? a LiION? can you link us to one online or something? i've never even heard of that... a small battery that tucks away nicely sounds ideal.

 

Re: 1980 XJ Cafe Project

ZAP, I have been looking for a replacement for the keyed ignition that will fit that hole for the right side and for the left side its going to be a false switch of some sorts. (I like uniformity side to side on bikes)

Dude, the battery is a Shorai, it has held up just fine, I have been riding for the last two months and have never had it not fire right p for me. I think the model i got was a LFX14L2-BS12. It is super small and provides just enough juice to start these bikes very well.

I have finally gotten the headers wrapped and am currently color sanding the tank and tail section. I have been stupid busy moving and with my new job (Training to be a pilot) that I have been so far behind on finishing this project. But the tank and the tail section color sanding is the final step, so hopefully soon.

Coming up next im building an XS650 tracker for my dad. His first bike was an 89 XS650, so this will be fun! I will post glamor shots hopefully this weekend of the bike.

 

Re: 1980 XJ Cafe Project

I never did find out what the problem was with the clutch. After removing and rebuilding and checking the clutch basket, springs, bolts, cable and adjusting it got knows how many times, it just magically went away. Ive been riding it about two - three times a week with absolutely zero issues. The bike screams all the way to red line, does not stumble or hesitate any more and is a dream to ride. I get tons of looks and comments about it. Hoping to take it to a show sometime to show it off.

 

OK guys, finally got some nice pictures of my completed bike. (I say "completed" very loosely)

















Let me know what you guys think.
-Chris

 

Me likey a lot! Don't normally like the way pods look on these bikes (much less what they do to carb function) but on this one they work (visually) just perfect.

I think you've struck a good balance between old & new tech too, loving the front end and the pipes in particular... Are those levers Pazzo or MIX pazzo style by the way? Got a pair of MIX ones on the NC27 and they're nice.

 

Looks nice, the only thing I would do is run a piece of sheet metal, plastic or fiberglass from the tab at the end of the tank back towards the tail along the bottom of the seat.

 

I think personally I'd have trimmed the tabs off in line with the tanks seam, but that would work too...