81 XJ550 Cafe build

Finished the last project so I thought I would try my hand at an old XJ550. Purchased from the local wrecker it will keep me busy and out of trouble for quite some time.

 

It was in rough shape.

 

Thought I would start by striping it down and having a good look.

 

Took the carbs off, gave them a really good clean. also got the front wheel off and took to it with a sander and paint. Also fitted a new Avon front tyre.

 

I can sprayed the tank and a few other bits and pieces. The goal for the moment is to get everything working and the look and lines the way I want.

 

if its got the word cafe in the title i'm subscribed! looks great so far. will be tuning in often on this so plz keep us posted

 

The original front end is up the sh*t. The forks are badly pitted, seals are busted, brake piston, seals and master are toast. I found a cheap 650 front end and swapped it over. The forks are diffrent sizes so I found new clip ons from a cbr250r. The triple fits, but is a little longer in the stem. As soon as the enginers open ill have him press out the stem from the 550 and press it into the 650 triple. The headlight mounts were now stuffed and had to get after market mounts. Heres a photo of the 650 front end.

 

I sprayed the exhaust and the old rear set bracket. I put the exhaust back on and im fairly happy with it. I think it will come back off eventually and ill go with something more retro. I dropped the headlight on the concrete so ill have to get a new glass. I yelled F&*k so loud my neighbour rang to see if I was ok. All part of the fun I guess. Im also looking at styles for a potential seat.

I put the clip ons under the triple and im fairly happy with the look.

Does anyone have any photos of a 550 fitted with a nitroheads seat or maybe and old norton commando seat?

 

LOOKING GOOD so far!!! Have given some thought to painting the wheels. Always wondered if you do that, how much of a problem is chipping the paint when you have to change a tire???

skillet

 

i just rattle canned mine for the moment. i know it will probaly get messed up when it comes time to change tires but spray paint is cheap. other alternative would to be get them powdered coated. WAY more durable.

 

Thanks for the kind comments guys. SKILLET the rims will mark when they fit the tyres but im not to worried at the moment. The main goal is to get it running and styled the way I want. Once all is done and im happy with the look and the paint combinations, I will strip the whole thing and hit it with powder coat and chrome.

KOOKIE im looking forward to seeing the tail on your bike in the day light. Looking good so far.

 

Good start!! Some constructive critsizm...
Might I suggest rounding that front fender on the ends just a bit? It looks too "chopped" off from here.
That tank just doesn't do anything for it either. You should find a more tear drop shaped tank for the project (Maxim tank) and it would fit the lines of the bike alot better.
Once it's done, it'll be a blast to ride.

 

I do agree with PainterD on the front fender in that it should probaly be rounded off but as far as the tank goes I say stick with the one you got. I only say this becuz you say your going with a cafe style bike and if you look at alot of them the tanks are a lil more squared with the indentions on the side to tuck your knees into. I like these tanks. If I was building a bobber/ chopper I would go with a tear shaped tank. That's just my $0.02

 

Yeah, stick with the SECA tank. OR, if you change your mind, give ME the SECA tank! :wink:

Seriously though, keep up the good work! I'm building something very similar.

 

If you want to add a bit of contrast to the tank and look a bit
"Old School" you could always stick on a set of tank rubbers. Might look good on those knee cutouts that are on the stock tank. Plus they help hold you on if you intend to do some corner carving.
I found these by Googling "Tank Rubbers"

 

Yes, I guess the Seca style tank would go better for the cafe style "look". I guess I'm not into the cafe style myself (to each his own) I just like the tear-drop shape, that's all. Whatever melts yer wax.

 

I like Maxim-X's idea! Also, I traded my Seca tank to another member for his Maxim tank. He was going for "cafe style" bike. We were both happy with the swap...

skillet

 

Pretty much the same thing I did. The Maxim tank was a perfect replacement for the old Seca tank with no mods, just set it on!

 

Went to a cafe site and found a little inspiration for ya

A link, XJ is at the bottom:
http://www.dotheton.com/forum/index.php ... #msg221112


....and lastly a link to a Seca build that may inspire you:
http://www.dotheton.com/forum/index.php?topic=466.0
Here's a link to the DTT website you may want to browse:
http://www.dotheton.com/forum/index.php?action=search2

 

The first bike is a NICE example of a "Brat" style. I like it!!!

skillet

 

Looking good so far 8) Always interested cafed 550, have been planning to do it to my own for a long time too, but haven't got done nothing so far I think too that Seca tank fit much better to theme than Maxim tank...

 

looks great!

hey, I like that luggage rack you have pictured in the pre-build. I've been looking for a way to increase my carrying capacity without widening the bike.

Interested in parting with it? I'll PM you

 

Thanks for all the feed back. I spent most of the week swearing at elictrical problems. I have picked up a new headlight that is smaller than the original. I also picked up a new front guard that I was going to cut down but im starting to like it. Currently im yelling at suspension.

 

was that fender for a larger wheel. just curious becuz of how it flares out like that in the rear (you'll probably take care of that anyway lol)

 

Maybe that fender was originally meant to be other way around?

 

^^^^^

+What Mikko said

 

yeah you guys are right i think it is suppose to be the other way around.

 

Thanks guys...it is manufactured to go the other way round. I was unhappy with the way it sat but ill show you a pick anyway. I think I will shorten it down. Its just sitting between the fork leg for the photos as I have to drill some new holes.

 

I was tooling around the this afternoon and had to think of new way to mount the indicators after replacing the old head light. I made up some dodgy brackets to check and idea. Can anyone tell me if this will cause drama with the fork clamp. The screw mounts all the way into the clamp so I cant predict any drama.

 

For what it's worth, I'd personally find another bolt that adds the thickness of the material used in that bracket and then torque the pinch bolt to spec.
From the picture that flat bar looks to be @ 3/16 of an inch thick, so get a bolt about 3/16 longer than stock.

 

That round headlight is *the* thing, man! I am old school, like them big, round and chrome plated!
Your build is looking really cool - go for it.
Aharon

 

Have the front end sorted so that im fairly happy. The new headlight opens up the front nicely.

 

Is that a speedo on the can to the right?

 

Hi Aharon., yes mate that is the speedo. It has turn signal, neutral, oil temp, and high beam indicator lights built in. Just have to wire it up.