41Y low budget caferacer

Been busy on this bike for a couple of months now. Hardest part was to fit the tank but it worked out.

Still a lot of work to do.

Will upload more detailed pictures today.

 

This is how I bought the bike

 

Talking about the tank, it was quite a challenge to make it fit.

1st step: remove the old brackets and weld in new ones


2nd step: relocate fuel petcock. In the old situation the petcock hit the frame.


3rd step: make it flow with the lines of the bike (i welded in an end-plate on the backside)


Then I painted the whole thing with rattle cans and finished it off with 2k clear coat

 

Some more detailed pictures

selection of my favourite tools


welded on subframe + seat pan



ugly crown plate


removing all unnecessary metal


result: flat crown plate


revised front fork and shortened it by 7cm

 

Looks great! Nice attention to detail.

 

looks like a beauty!

 

I like those wheels
Cheers, 50gary

 

Working on the speedo + painted exhaust

 

Sorry for not posting in 100% chronologic order.

Rebuilt + tuned carburators:






Made some plates to cover up the space between the subframe and seat:


Painted the gas tank with rattle cans (€32,- paint job, included 2k clear coat from rattle can)

 

Hi, nice job. so far so good. So what was the 'new' tank from - clearly not the original yamaha!

 

It's a modified Benelli Mojave tank.

 

So I finished the 'exterior' today.

Now I'm busy with the wire loom etc.

 

That looks about as light as you can make a 900.
How does it run, did you buy a commercial jet kit or trial and error?
Oops just read back a post, not wired yet. Never mind.

 

Correct, I am busy with the wiring at the moment!

The bikes feels 100kg lighter. There is not a lot of room to shave off more weight indeed.

 

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About the Jets: from experience i enlarged the mains with 10% and the slows with 8%.

 

Are you planning on venting rectifier or is it staying completely sealed under the seat? I initially planned on putting mine under the seat as well but then changed my mind due to it needing air flow for cooling.

 

Please tell me where the air flow is coming from on the stock location..

 

I don’t remember if stock bike had air channeled into stock location but I know for a fact that it wasn’t sealed unlike your set up of electrical area. Btw, I mounded everything except rectifier under the seat as well.

 

Maybe ill put a computer fan on top of it

 

Don't make the brakes too sharp - you could lose and important part of your 'old chap' on that tank seam..

 

I was going to comment on that as well! My thought was the seat should have a front lip as well (my FZR has one to pad the tank).

 

Update.. installed the 'exhausts' and finished the wiring.

 

Looks great, this going to be a rider or for a show bike? Looking forward to how it rides and handles.

 

I like the building more than the riding however in the summer I drive often near the city (going for an ice cream etc.) . I rarely make long trips. Dont think a long trip would be a pleasure on this thing anyway lol..

 

Whereabouts in NL are you?

 

I'm from the south.

Finished the brakes yesterday. Installed the 19RCS brake pump and custom HEL brake lines.

Should mention the build passed the 'low budget' stage a bit..

 

Adjusted the valves and finished the wiring harness.. And yes.. I did figgle in the brake light wires inside the main loom.

 

It's alive!

 

How did you like the fit and finish of the Hel lines? Looking for a set for my FZR1000 and that name has come up.

 

It's superb. You can twist the banjo fittings in any direction so you can always mount it tentionless. Highly recommended.

 

South NL eh? Must be near the Belgium border with those Leffe bottles in the background! I hoped you cracked a couple when it started. My company HQ is Eindhoven so been visiting for 30 odd years now.

 

Haha good pair of eyes!

10min from the border (30 from Eindhoven) so yes we like a good leffe (or other Belgium beers).

 

So I drove about 10km yesterday. It is super fast because it is so light but the idle is not good. It stalls after a while. I suspect a vacuum leak (I did replace the intake gaskets and covered them in gasket-improver). Maybe it is because the carbs are from a different bike and not synced yet..

 

It is more or less finished. Only have to fix some minor issues.

 

So today I finished the project completely.

Of course running pods is not ideal but it drives pretty well for having those pod filters. The fun thing about this project is that it is super lightweight. It is super fast and handles super good.

 

Looks nice.. although I'm not a fan of the side-mount number plates.. Did you weigh it? Would be interesting to know how many Kgs (lbs) you managed to trim off.