Wow, guys... these are all great bikes!
Congrats to all the noms!
And pa23driver, thanks for the vote of confidence and kind remarks.
By way of some brief background, I don't have a "build thread" per se, as I never considered my project to be a "build" in the usual context, but I suppose it's been more of a "resuscitation project". I do have a work list, though, that I have been maintaining as a kind of project history.
Since August '07, when I brought my bike home in the back of a pick-up as a non-running, smelly, leaky paperweight (but basically sound, platform for a mild cafe- roadster), I have done the work that follows, under the patient guidance of others here and at the former 650rider.com. I am by no means a natural mechanic, and have particular difficulty grasping matters electrical or electronic, in particular. But I'm persistent, and I had an image in my head of the cafe-roadster "crossbreed" that I wanted to wind up with. One day, I'd like to pull the motor out of the frame and go learn how to go through it to see to its absolute soundness once and for all, but at the moment I'll just have to optimistically mind a minor oil weep or two, and address them as needed, which has been working for me thus far.
This bike was built the year that I graduated from high school, a wide-eyed 18 year-old in whose house motorcycles were forbidden. All I could do back then, in terms of getting close to a bike like this (or any motorcycle) was stare and daydream. But in 2006, I got my endorsement as a sort of "self-enrichment" endeavor, and became the proud owner of a 2005 Kwak Ninja 250R, which I still own. The TX came along late the following summer as a "light fixer-upper" non-runner. Little did I know what I was getting into. But now she starts on the first hot kick, and I don't have to tell any of you about the sound and feel of being pushed back against the bumstop when you roll on the throttle of a healthy 650 twin. Sure, there have been times when I wanted to kick her over in the middle of the street. But as I write this, I'm glad I didn't.
Once again, I offer my gratitude to the innumerable folks here (and in the former 650rider.com) who have assisted (and continue to assist) me on this project, as well as our generous forum host(s).
Cheers!
TC
Aesthetics/Function/Handling
- new tires (Kenda Challenger Sport)
- new clubman bars
- new cafe/solo saddle
- pillion pegs removed
- new reverse cone "shorty" mufflers w/handmade custom fitted aluminum hangers
- new cafe/bobber tail light/tag frame combo (
NOTE: Due to damage to rear fender and tail light/tag combo (Feb '12), bobbed existing fender and installed Mike's tail light/tag combo #11-2342.)
- installed bungee knobs (re-purposed swingarm spools) on rear fender/bungee net
- new grips
- new Napoleon trapezoidal bar-end mirrors
- new XS Performance cam-end and alternator covers
- matte polished fork lowers and rear hub
- re-blacked left/right engine case covers
- wrapped exhaust headers
- installed heat resistant covers on plug wires/caps
- replaced all peg/shifter/kick rubbers
- replaced fuel tank rear rubber mount
- black leather tool roll (mounted forward of saddle bumstop) containing CruzTools road kit/incidentals
- ShockSox road bike fork seal dust covers (black)
- painted rear brake stabilizer arm and actuator rod Rustoleum Aluminum
- National Cycle flyscreen
- handmade aluminum gauge visors
- handmade aluminum crank case (top) reflector plate
Electrical
- replaced brake light switch - front
- replaced brake light switch - rear
- replaced brushes
- new PAMCO electronic ignition trigger/dual point coil/wires/caps/iridium plugs (
NOTE: Due to unexplained failure of Mike's coil #17-6803 (Jan '12), replaced it with Mike's #17-6822, with less voltage, but smaller and with built-in, rearward-facing wires. Also reverted to stock NGK plugs w/stock gap of .028).
- installed bar-mounted voltage gauge
- new solid state regulator/rectifier
- new sealed AGM battery
- replaced grommets in headlamp bucket
- properly installed (soldered/heatshrunk) poorly installed 20 amp blade-type main fuse
- replaced broken '77 hi-/low-beam, horn, turn signal control switch with new '77 switch
- installed Bike Master short-stalk turn signals w/custom brackets front and rear
- 552 signal flasher relay
Mechanical/Fuel/Lubrication
- new left/right fuel tank petcocks
- replaced crankshaft seal
- replaced output shaft seal
- replaced all cables
- cleaned (multiple times) and synched carbs, set float height
- replaced needle/seat combos in both carbs
- new clear fuel line with in-line conical fuel filters
- replaced Advance Timing Unit, serviced rod
- replaced clutch actuator unit (includes worm gear)
- replaced clutch lever and perch (summer '11)
- new intake manifolds
- replaced phillips screws in carb bowls with allen heads for on-bike bowl-removal
- new XS Performance pod air filters
- replaced stock upper oil filter with billet aluminum XS Performance oil cooler/filter
- replaced sump filter
- designed (using PAMCO Pete's original concept) and installed experimental (Spectre Performance Products) cold air plenums for head temperature reduction
- installed reed breather valve, hose, and filter for creation/maintenance of crankcase vacuum and minimization of oil leaks
- replaced oil plug copper crush washers
- replaced missing cork ring for timing chain dome cover
- added rare earth magnets to outside of fuel tank, just forward of petcocks, to minimize migration of metallic sediment into fuel system
- see front brake rehab (below)
- added RR dipstick oil temperature gauge
- re-torqued cylinder head/replaced notoriously weak OEM rubber coated washers (under four outer acorn nuts) with brass, as well as under inner four. Remainder were replaced with Grade 8 steel washers. (January 2012)
- replaced leaking timing chain adjuster case gasket, removed black paint from case, inspected adjuster mechanism (exhibited little to no wear on idler wheel or plastic traveler) (April 2012)
-------------------------------------
October 2010 - Mikuni VM 36mm RS Single Carb Conversion Project (installation/dial-in):
- Wiseguy Customs 2-into-1 chrome ceramic-coated intake manifold (cafe/tracker configuration)
- air screw currently @1 turn out
- main air correction jet in intake bell: removed
- pilot jet: 25
- main jet: 200
- 159-P8 needle jet/6F9 needle (clip in middle slot)
- left side cover modified to accommodate single carb
- Mike's XS oval pod filter w/ custom aluminum air shroud
- single in-line Purolator F10024 (one-piece, all metal) fuel filter (January 2012; replaces easily damaged plastic conical fuel filters)
- Motion-Pro 1/4" fuel line
August 2011 - Front Brake Rehab:
- New stock-type master cylinder (Mike's XS)
- New upper/lower hoses (Mike's XS)
- Rebuilt original caliper with seal kit from Mike's XS; repainted w/gloss black caliper paint
Here are a few more pics... a couple laterals and detail shots: