Pumba the XJ750 project

Whoa! My head hurts just thinking about going that deep. Looks like one of those long winter days out in the shop for that kind of trickery to be accomplished.
Thanks for posting. That's one for the future tinkering when I'm all alone and looking for something to do in the off season. Atleast a good option now anyway.

 

The best things about projects is the ability to change ideas as you go along, things can evolve, and you can try something and hate it and move on.
The rear section of Pumba is currently on hold due to the fact my ideas look pigdog ugly :lol:
Plan b may evolve from it and work. :mellow:

I had a friend with a lathe make some spacers for the bars.
This was required due to my choice of switches. They were for fatter cruiser bars, and I didn't want thicker bars because it would mean different saddles and brake and clutch mounts.
Gav has machined up some nice spacers that fit the bill very well

At last a final fit up of the bars and switches;


The indicators are just sitting there for ideas, and now I have to design the Koso dash mount.
This is not a simple matter due to the fact I am considering adding a GPS, but I'm not even sure I want it.

Bar ends ordered today from Ebay as well as mirror mounts.

This week I have to decide on front brakes, almost certain to go with early R6/R1 complete system

 

Todays effort
From template, Koso Bracket and alloy plate;



To XJ750 koso mount


Very happy with the outcome


Single wiring plug for the instruments...

 

looks an awful lot like what I'm about to do.
I think I'll crack open the new gage cluster and paint in the 10k redline.

 

dang man, that's bad ass

 

Looking great! Very professional and clean.

 

Very nice looking project - keep updating. Thanks especially for the resistance info on the fuel level sender unit - I'd like to swap out my gauges eventually, and love the look of those. Any modifications necessary for tach? Looks like speedo reading can be changed in the unit to account for various wheel sizes. Also, does the panel happen to have a thermometer on it (air temperature)?

Very nice work.

 

The tach has options for coil neg or sensor pick up, and can be configured for dual fire coils and multiple cylinders. Dash has 2 temp inputs and I will probably use one for oil temp and one for cylinder Head temp. You could use them for any temp with the right sensor.

 

While waiting for brake parts I went back to trying to paint. And I've had it ! By the time I get the finish good enough I will have spent heaps on
spray cans and spent 60 odd hours to achieve an inferior finish that will wear off as soon as I put a tank bag on it.

Thats it, the towel is thrown.

Time to put aside a budget to get the paint done properly.

However the color scheme I have tried seems to work for me, and the look i'm trying for.

I decided to fit up some of the bits for some photos, as Pumba is getting the stripped back down for the front brake upgrade (R1 brakes FTW!), diff overhaul and the change to the different style rear wheel.

So the current look (which may change upon reassembly).





I lowered the instrument mount as I didn't like how it sat too high.



Of course the switches touch the tank


Now its strip down time again

Believe it or not, I do want to get Pumba on the road, but the amount of things I find to recondition/upgrade is amazing.

 

Looking good! and Shiny forks!
Do you really need to turn the handlebars anyway? I see lots of arc shaped rubberized marks on your driveway, in your future!

 

Great looking build.

What did you rewind the fuel sender with? I've got one that's broke and would like to redo it.

 

I rewound the sender with the original resistance wire, as my target resistance for the new fuel gauge was lower resistance, so I just had to shorten it.

How bad is your old sender? If there is a single break maybe you could get by with just a solder job?

 

I found one from Summit that I can mount onto the bracket that goes in the tank. I'm building an LED guage. I'm just about done and will do a write up on it.

 

Things have been happening slowly but surely. Finally finished the fork rebuild including servicing the anti dive units.

The R1 disc upgrade (new bearings and seals);


Anti-dive valves;


And a few more new bits;


Next update will hopefully be pics of the finished front end complete with the R1 calipers etc.

 

UPDATE PLEASE?

lol sorry I want to know how this brake setup turns out. My bike could really benefit from the R1 brake setup and some stiffer fork springs.

 

Did you get th brake shoes in Oz?

 

From the UK via Ebay

Hope to have some major updates and pics in the next week or 2.

Another order winging its way to me from Chacal...

**** BIG plug for XJ4Ever parts*****

Should have the caliper adapters soonish
New seat cover currently getting made by B&H Specialties.

 

Look forward to the next progress report and pics. Looking good. NigeW

 

A bit of an update, hopefully a lot more will be done in the next 2 days


I am now at the final assembly stage, so now everything gets pulled apart again :laugh:

This is so everything gets checked and tensioned as it goes together.

The spare engine (low Klm Police bike engine) is off to Gav at GD engineering for a strip down - if i find the time to do the engine work myself this project will never finish. If it only needs a freshen up, I will use that engine for initial rego. If it needs a lot of work, I will rego with the unknown engine, and spend time building up a keeper engine.

Some more parts have arrived (XJ4Ever)

Most of these parts are to make sure Pumba is reliable.

New filters and cables;



Cheap blanking plates so I can put a liner kit in the tank easily, fuel tap, breather hose, correct front brake rotor bolts, brushes for both the alternator and starter motor and some other odds and ends .


And the cheap mirrors I have decided on for now ^_^

 

glad to see its all coming together will be just like a new one when you finish. question for you since you changed the controls how did you rig up your choke