1980 Bobber Build on Mr. Lucky's Frame

[kvanderploeg]

I've been documenting and showing some pics over on the V-Star 1100 forum but I figured I should document the process over here as well. I bought a 1980 with cast wheels, disc F&R, and ~20,000 miles for $975. It does run, but the battery is shot. Also, at about half throttle, it would cut out like it's running on one cylinder. This will be a build for my wife to ride, but I'm sure I'll just have to take it out for a spin now and then. Here's where we started:

A garage full of Yamahas. Front to back, 1980 XS650, 2007 V-Star 1100, 2007 Stratoliner.

 

[kvanderploeg]

First thing to sort out was that throttle cutting out issue. I found from xjwmx a thread about his issues with the TCI box, and it sounded pretty similar to my issues. I bought $2 worth of diodes from Radio Shack and fired up the soldering iron.

The inside of my TCI box:

A closer shot of the 4 diodes I replaced in the upper right hand corner of the box:

The old "spider egg" diodes that were removed:

This did the trick, running like a champ now!

 

[kvanderploeg]

With winter fast approaching, I needed to do a lot of work to my garage to get it ready for all the time I'll be spending out there. First on my list was lighting. I had a 4' 2 Bulb T12 fixture that wouldn't turn on under 50° and the two bulbs in my garage door opener. That wasn't going to cut it. I hung 6 - 4' 2 Bulb T8 fixtures that are rated for 0° start with 6500°K daylight bulbs in them. I also changed out the ballast on my original fixture to a similar ballast and the same T8 bulbs. What an amazing difference. Don't know why I didn't do this sooner.

Before:

After:

I had an exterior wall of my garage that was not insulated or drywalled. Spent a fair amount of time getting that insulated and drywalled, and cleaning and organizing the garage in the process. I also built some shelving out of a couple of 2x4 Basics kits. Excellent shelving and very strong.

Now that it's done, I can move on to more exciting things!

 

[kvanderploeg]

Along the way, I ordered a frame from Mr. Lucky's built by Paughco. Seems like it's well built.

 

[kvanderploeg]

Started tearing into the bike a bit. I wanted to get the oil (and sludge) out along with the old gas. I had placed an order for a bunch of parts I figured I would need, gaskets, rubber parts, carb kits, filters, etc. I've been keeping track of all the expenses in a spreadsheet, though I probably won't want to see the number at the bottom when I'm done.

I drained the old oil, and pulled the lower oil filter cover. As usual, the filter had a major blowout. I cleaned out all the sludge and nasties, applied several coatings of gasket remover, and cleaned up the mating surfaces. As I put the cover back on, one of the M6 screws snapped off. I pulled the remaining screws, and there was just a bit of thread still sticking out of the block. I clamped on my best vise grips, and turned it out. Went to the hardware store for 6 new M6 screws. Lesson learned here, don't trust 30+ year old hardware.

A few pics of Saturday's progress:

 

[kvanderploeg]

Sunday, I wanted to focus on getting the tank off. I had let the fuel drain out the day before, but I let the tank continue to dribble out into a catch cup overnight. The fuel filter looked like it had rocks in it. Surprisingly, the filter was made in Chicago. I bet that company is no longer in business, at least not in Chicago. At least all the nasty stuff was on the right side of the screen.

Tank off, wiring harness pulled, and headlight off.

 

[kvanderploeg]

I did a little work before dinner last night. More gasket removal, which tends to be a process of scrape a little, put on some gasket remover, work on something else for a while, scrape a little, etc. I managed to pull the rear wheel, chain guard, carbs, and carb mounts. I also put new plug caps on the stock coil before throwing it into the "Reuse" pile. I also loosened all the engine mount bolts and removed the head stay assembly.

The new carb mounts from Don James at www.jbmindustries.com. I emailed him to see when he would have mounts available again, and he scrounged up a set of cores and molded a pair up for me. Thanks, Don!

 

[Two Wheel Mafia]

What did that frame run you price wise?

 

[kvanderploeg]

$799

http://www.mrluckys.biz/XS-650-Yama...-1982-Yamaha-XS-650-Engines/product_info.html

Kent

 

[Tech7]

What's the stretch and rake on that frame?

 

[kvanderploeg]

30° rake, not sure on the stretch.

Kent

 

[Tech7]

Thanks. Pretty good deal for $799. Good luck with the build.

 

[kvanderploeg]

Thanks! Hope it keeps me from going stir crazy this winter.

 

[Two Wheel Mafia]

Thanks for all the frame info... It looks great and is a very good price for the style.

 

[kvanderploeg]

Thanks! Looking forward to seeing some mock up.

Kent

 

[swbill]

For $800 I would expect a frame built by someone that can weld. Those are some of the nastiest welds I have seen on a "professionally" built frame. I'm sure it's gonna be cool ride when done though.

 

[kvanderploeg]

Well, I set out to replace the clutch pushrod bushing, seal, and convert to the one piece pushrod tonight. I had the perfect sized rare earth magnet that I bought in a 10 pack from Harbor Freight that fit perfectly on the end on the old outer pushrod. I was able to get the ball bearing with it, but I just couldn't get the inner pushrod. I pushed it back in and drilled out the bushing, then it came out. I chamfered the outer lip, put on some Threebond, and slowly pushed it in. I think I got it on the first try. Would I be able to tell if I really screwed it up? It seemed like it went in fine. I put in the new pushrod and buttoned it back up before dinner.

Kent

 

[99orton]

Seems I have seen these pictures before. Hey KV!

 

[kvanderploeg]

Hey Donn! Yea, figured I might as well document the process...

Kent

 

[kvanderploeg]

Some more progress today. Engine went in with only a little persuasion from the BFH.

It's a roller!

Ok, so now it's a roller.

My impression of the Grape Ape.

Should have seen the look on my wife's face when she came home today!

Kent