82 XJ650 Cafe Build

This is what she looked like when I picked her up!

Phase 1: put on new tank and pulled off stock shocks

Installed new taller shocks

I've got a seat pan/tailpiece being built now and the battery will be relocated in the tail. Airbox will be coming out and pods will be put in place, it's going to be a headache to tune the carbs I know but it will be worth it.

 

Glad ya' found a tank that would fit. Keep us updated with pics...

skillet

 

Thanks! Had to do a little frame mod to get it to fit, don't have pics of that right now.... I believe the tank is from an old BSA but I'm not 100%. Getting ready to place an order for some drag bars, bar end mirror, and fork gaiters. Not sure yet about head light and tail light options.

 

Just a quick thought, I'd hate to see you get "bit" after sinking a bunch of time, money and effort into the bike:

Have you put the valves in spec and done a compression test so you know you're "building" on a viable platform?

We've had more than one member finish a really nice-LOOKING project only to discover that his motor has a bad cylinder or two when he finally got around to trying to make it run right.

 

Been a while since I've posted an update, been making slow progress since I started my new job and whatnot. Got the airbox pulled out and pod filters installed. Did some touch up paint on the frame, installed new handle bars and fork gaiters and got the gauges put back on. Got my new battery today, going to run all the wiring tomorrow and then she'll be almost ready to start up.

 

Make sure your rear wheel spins without binding the u-joint.
When I was building my café, I put larger shock in the back, and the wheel did not turn at all. I had to build a custom sub-frame to run the larger shocks and create the illusion of the back being lifted.

 

Thanks Samson! From what I can tell so far just from rolling it around the shop it seems to spin fine. The shocks are longer but I think they're also softer, it doesn't really sit very much higher than stock.

 

im new to the forum. just want to say nice progress. seen some killer bikes on this site, great tips and suggestions on builds. getting alot of great ideas. thanks guys!

 

I'm about to order some exhaust wrap, I've never wrapped pipes before so I have no idea how much I'll need and don't want to low ball myself..... will 50 ft of wrap be enough or should I order more?

 

I used 50 ft of wrap for my 4-1 exhaust, lapping 50%.

 

Here's a couple of shots of it, had to retap one of the exhaust stud holes today.... I worked on reshaping my tail piece but don't have any pictures of it yet, it will follow the shape of the tank a little more and also fully cover the battery.

 

I got my tail piece about 90% finished at this point..... also got the seat pan shaped to the frame!

 

Cool build, what are you doing to replace the bracing you chopped out?

 

Are you talking about the bracing in the rear subframe? It's still there, used it as part of my new battery bracket

 

I'm building an XJ750 Cafe Racer (Just about to make my thread), I'll subscribe to yours!

 

Sneak peek..... gonna be fabbing these up into foot pegs. Not exactly sure how yet, but I'm taking them into the shop Monday and not leaving till they're done!

 

Got the foot pegs fabricated today! I need to get better at taking pictures in progress. I took the pedals and stock mounts to my friend's shop because I don't know how to weld and this is what we came up with!

We cut the stock foot pegs off the extension arm, then welded a square piece of steel where the pivot was for the stock peg. Then welded a steel bolt to the square piece of steel, that runs through the pedal and has a flanged lock nut holding it in place!

 

cool man. i would have never have thought of that. so they spin right... i have those same pedals on my mountain bike.

 

Been a while since I updated! My tailpiece is finally finished, minus paint. Also exhaust is back on.

Before starting this I had no idea how to do wiring, it's been a slow process but I've got my wiring all redone.... still trying to figure out the best way to minimize the appearance of all the wiring without running it through the frame.

Also decided to cut the front fender to create a fork brace/mini fender, going to be painted black

 

Coming along nicely. Keep on it.