My rephased Cafe Racer build is complete

C-Los SD · 08-07-2011, 08:16 PM

Finally finished my 77 rephased cafe racer.

This is what it looked like when I bought it last year. These pictures are in random order, I should have did a better job of documenting my build.

I cut off the rear loop and made a battery and electronics tray.

700cc JE Pistons

Freshly painted frame...single stage

Battery tray and solenoid. The Shorai Battery easily turns the motor over

I don't like how this looks, but it I couldn't think of a cleaner way of a fuse block

The coil brackets from Joker Machine work great

Almost there

Home made rearset brackets

Final product

Here is what is sounds like

http://www.youtube.com/watch?v=7joU_9ZE6Zc

I'm getting a lot of noise from the head area. I hope I just need a valve adjustment and it's not something serious. Anyone have any thought on the noise?

azman857 · 08-07-2011, 08:26 PM

Thats Niiice! I likey!

Greg-NWO · 08-07-2011, 08:26 PM

Wow!! That is really, really nice!!!

Where did you get those velocity stacks?

Amazing job! Top notch!

TeeCat · 08-07-2011, 08:38 PM

VERY nice!!!!

TC

tonyc · 08-07-2011, 08:46 PM

That is superior work. Beautiful bike. Enjoy.

C-Los SD · 08-07-2011, 08:50 PM

Forgot to list the mods.

Hugh's rephased 277 crank and cam
JE 700cc piston
Pamco Ignition
PMA swap
Mikuni VM34 carbs
Steel Dragon Performace V-stacks
Redwing Hammerhead Shocks
Race Tech cartridge emulators...these work great
Happy Dan's Brembo caliper bracket
Brembo Monster caliper
Honda CB750 master cylinder
XS750 Gas tank with Monza Gas cap
Airtech Streamline bubble tail
Motolanna triple clamp
Magura clip-ons

Lots of polishing

retiredgentleman · 08-07-2011, 08:56 PM

First class workmanship.....................well done

Noise....................check that your camshaft chain tension adjuster has the "damper" washer.

hmusket · 08-07-2011, 09:08 PM

Too good looking to ride! Put it under a glass cube in the living room.

CDNTX650 · 08-07-2011, 09:21 PM

real nice work man. show worthy forsure.

C-Los SD · 08-07-2011, 10:06 PM

........

C-Los SD · 08-07-2011, 10:08 PM

Quote:

Originally Posted by retiredgentleman

First class workmanship.....................well done

Noise....................check that your camshaft chain tension adjuster has the "damper" washer.

I'll check the damper, what does it look like? can't really tell from the parts manual picture...is it rubber? I have that planishing hammer sound effect that goes up with engine revs. Hopefully that is my problem. Thanks!

Ironsled77 · 08-07-2011, 10:31 PM

Saaaaaaaweet!!

Posted via Mobile

jamesgs4 · 08-07-2011, 10:35 PM

Very nice! so fresh and clean!

retiredgentleman · 08-07-2011, 10:56 PM

Quote:

Originally Posted by C-Los SD

I'll check the damper, what does it look like? can't really tell from the parts manual picture...is it rubber? I have that planishing hammer sound effect that goes up with engine revs. Hopefully that is my problem. Thanks!

The damper was missing from my bike. I found an old copper washer in my spare parts and drilled the centre hole slightly larger......................... it quieted my engine. I believe Mikesxs sells one that has rubber in it.

Where did you buy the Brembo caliper, and is that an OEM brake disk?

jay760 · 08-08-2011, 01:32 AM

What compression are those pistons? unusual to see over size pistons with no flat lip around the edge, I've got a set of 78mm in mine with a lip around the edge, would have thought they might have hit the head, what head gasket did you use? Hoos says to use standard.

thrashin · 08-08-2011, 05:15 AM

that is soooo purdy.

xsPete · 08-08-2011, 05:27 AM

Quote:

Originally Posted by C-Los SD

Finally finished my 77 rephased cafe racer.

This is what it looked like when I bought it last year. These pictures are in random order, I should have did a better job of documenting my build.

I cut off the rear loop and made a battery and electronics tray.

700cc JE Pistons

Freshly painted frame...single stage

Battery tray and solenoid. The Shorai Battery easily turns the motor over

I don't like how this looks, but it I couldn't think of a cleaner way of a fuse block

The coil brackets from Joker Machine work great

Almost there

Home made rearset brackets

Final product

Here is what is sounds like

http://www.youtube.com/watch?v=7joU_9ZE6Zc

I'm getting a lot of noise from the head area. I hope I just need a valve adjustment and it's not something serious. Anyone have any thought on the noise?

You gotta be proud of that, the attention to detail is brilliant, enjoy it

irristeve · 08-08-2011, 05:36 AM

very very very nice indeed, sex on wheels,how much drama is involved in fitting 750 tank & how much does it hold,hope its restored to be ridden & not hidden,very good result

Shiffty · 08-08-2011, 05:47 AM

Very nice job.

scott s · 08-08-2011, 06:01 AM

Have you tried just adjusting the valves and cam chain? After a fresh build/rebuild, it takes a bit for things to "take a set". I had to do it on my '75 right after the initial start up, even though it had been done on the bench.
Also, plan on doing it again at about 500-600 miles and re-torque the head.

Now...the bike is beautiful! The only thing I would change is the tuning fork emblem on the tank; it's just a little small, IMHO.

Is that one of the early '74-76 master cylinders? How does it work with the Brembo caliper? I'm having some soft brake issues with mine with stock caliper.

How do you like those grips? I just got a set for my CB500 but haven't installed them yet.

08-07-2011, 08:16 PM	#1
C-Los SD XS650 Addict Join Date: Mar 2010 Posts: 263	My rephased Cafe Racer build is complete Finally finished my 77 rephased cafe racer. This is what it looked like when I bought it last year. These pictures are in random order, I should have did a better job of documenting my build. I cut off the rear loop and made a battery and electronics tray. 700cc JE Pistons Freshly painted frame...single stage Battery tray and solenoid. The Shorai Battery easily turns the motor over I don't like how this looks, but it I couldn't think of a cleaner way of a fuse block The coil brackets from Joker Machine work great Almost there Home made rearset brackets Final product Here is what is sounds like http://www.youtube.com/watch?v=7joU_9ZE6Zc I'm getting a lot of noise from the head area. I hope I just need a valve adjustment and it's not something serious. Anyone have any thought on the noise?
C-Los SD XS650 Addict Join Date: Mar 2010 Posts: 263	Last edited by C-Los SD; 08-07-2011 at 08:33 PM.

08-07-2011, 08:26 PM	#2
azman857 XS650 Junkie Join Date: Feb 2010 Location: Tucson AZ Posts: 702	Re: My rephased Cafe Racer build is complete Thats Niiice! I likey!
	I don't have a plan and I'm sticking to it! '80 SG with CND needles (#4 slot)and jet, #45 pilot and 135 mains. Ditched the buckhorns and installed bars with wider grips. Stainless steel brake lines, Dual front disc brake, Radio Shack/Chrysler Rectifier Regulator. AGM battery. Pamco ignition with ultimate coil. More changes in progress

08-07-2011, 08:26 PM	#3
Greg-NWO XS650 Member Join Date: Aug 2010 Location: Kenora, ON Posts: 19	Re: My rephased Cafe Racer build is complete Wow!! That is really, really nice!!! Where did you get those velocity stacks? Amazing job! Top notch!

08-07-2011, 08:38 PM	#4
TeeCat One-Mik Wonder Join Date: Jan 2010 Location: Central Maryland Posts: 1,616	Re: My rephased Cafe Racer build is complete VERY nice!!!! TC
	*1973 Yamaha TX650 single-carb Mild Cafe Roadster*

08-07-2011, 08:46 PM	#5
tonyc XS650 Junkie Join Date: Dec 2009 Location: Bakersfield, CA Posts: 885	Re: My rephased Cafe Racer build is complete That is superior work. Beautiful bike. Enjoy.
	1978 Stahdard 1976 standard 1963 BSA A-65

08-07-2011, 08:50 PM	#6
C-Los SD XS650 Addict Join Date: Mar 2010 Posts: 263	Re: My rephased Cafe Racer build is complete Forgot to list the mods. Hugh's rephased 277 crank and cam JE 700cc piston Pamco Ignition PMA swap Mikuni VM34 carbs Steel Dragon Performace V-stacks Redwing Hammerhead Shocks Race Tech cartridge emulators...these work great Happy Dan's Brembo caliper bracket Brembo Monster caliper Honda CB750 master cylinder XS750 Gas tank with Monza Gas cap Airtech Streamline bubble tail Motolanna triple clamp Magura clip-ons Lots of polishing

08-07-2011, 08:56 PM	#7
retiredgentleman XS650 Guru Join Date: Jan 2010 Location: Calgary Alberta, Canada Posts: 3,044	Re: My rephased Cafe Racer build is complete First class workmanship.....................well done Noise....................check that your camshaft chain tension adjuster has the "damper" washer.
	78SE, Pamco Ignition with E-advancer and Accel #140403S Coil, dual bridge rectifiers, VR-115 regulator, LED tail/brake, BS38 carbs, OEM air boxes, OEM manifolds, OEM exhaust, Heiden Oil filter/cooler, 17/33 gearing, analog voltmeter, Brembo 4 piston calipers front and rear, "All Balls" roller steering bearings

08-07-2011, 09:08 PM	#8
hmusket XS650 Addict Join Date: Oct 2009 Location: Marquette, MI Posts: 414	Re: My rephased Cafe Racer build is complete Too good looking to ride! Put it under a glass cube in the living room.

08-07-2011, 09:21 PM	#9
CDNTX650 XS650 Guru Join Date: Apr 2010 Location: Regina Sk. Canada Posts: 1,455	Re: My rephased Cafe Racer build is complete real nice work man. show worthy forsure.
	2010 Kawasaki Versys 1974 TX650A resto modded and done. 1978 KZ650 b1. Darn near stock, no restore.

08-07-2011, 10:06 PM	#10
C-Los SD XS650 Addict Join Date: Mar 2010 Posts: 263	Re: My rephased Cafe Racer build is complete ........

08-07-2011, 10:31 PM	#12
Ironsled77 XS650 GRAND HACK Join Date: Mar 2010 Location: Will County, IL Posts: 828	Re: My rephased Cafe Racer build is complete Saaaaaaaweet!! Posted via Mobile

08-07-2011, 10:35 PM	#13
jamesgs4 XS650 Guru Join Date: Feb 2010 Location: denver Posts: 1,812	Re: My rephased Cafe Racer build is complete Very nice! so fresh and clean!

08-08-2011, 01:32 AM	#15
jay760 XS650 Junkie Join Date: Oct 2009 Location: Somerset Posts: 671	Re: My rephased Cafe Racer build is complete What compression are those pistons? unusual to see over size pistons with no flat lip around the edge, I've got a set of 78mm in mine with a lip around the edge, would have thought they might have hit the head, what head gasket did you use? Hoos says to use standard.
	Last edited by jay760; 08-08-2011 at 02:11 AM.

08-08-2011, 05:15 AM	#16
thrashin XS650 Addict Join Date: Oct 2010 Location: Indianana Posts: 184	Re: My rephased Cafe Racer build is complete that is soooo purdy.

08-08-2011, 05:36 AM	#18
irristeve Grow old disgracfully Join Date: Mar 2010 Location: Cairns Qld.Australia Posts: 119	Re: My rephased Cafe Racer build is complete very very very nice indeed, sex on wheels,how much drama is involved in fitting 750 tank & how much does it hold,hope its restored to be ridden & not hidden,very good result

08-08-2011, 05:47 AM	#19
Shiffty Jim Wilson Join Date: May 2011 Location: Marion, Kansas Posts: 50	Re: My rephased Cafe Racer build is complete Very nice job.

08-08-2011, 06:01 AM	#20
scott s XS650 Addict Join Date: Feb 2010 Location: Rock Hill, SC Posts: 434	Re: My rephased Cafe Racer build is complete Have you tried just adjusting the valves and cam chain? After a fresh build/rebuild, it takes a bit for things to "take a set". I had to do it on my '75 right after the initial start up, even though it had been done on the bench. Also, plan on doing it again at about 500-600 miles and re-torque the head. Now...the bike is beautiful! The only thing I would change is the tuning fork emblem on the tank; it's just a little small, IMHO. Is that one of the early '74-76 master cylinders? How does it work with the Brembo caliper? I'm having some soft brake issues with mine with stock caliper. How do you like those grips? I just got a set for my CB500 but haven't installed them yet.

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