My cafe build so far...

[TROYCO]

I got this 84 heritage special back in November, was able to get it for free after rescuing it from a shed. To say the least, it had seen much better days. The frame was hacked up pretty good, I'm guessing in an attempt to lower it, they welded in some much thinner bar stock and repositioned the shock mounts with some angle iron and very questionable welds. Also added was a rear fender and a tail from some other mystery bike. Here's the frame of that bike after the teardown. Fortunately all is not lost, as this frame is the perfect candidate for a bobber build.

I picked up a frame and title from a 79 XS and a new wiring harness locally as a good base for this build. I took the engine out to give it a once over and replace some basic things like filters and some of the seals, the oil pump a new kick clip donated by another member (thanks weekendrider!) After some new bolts arrive it's going back together and hopefully fires up without issue.

I just picked up a new seat pan locally today and drug out the new frame and my tank to see how everything's going to look. So far I like the direction it's starting to take, and I think the seat pan fits in nicely with the look of the GS 450 tank.

 

[Square Circle]

Looks good, good choice for tank. How much did the seat set you back(if you don't mind me asking)?

 

[TROYCO]

Picked it up for $75. Used, but never installed. I was originally looking at a Carpy seat pan but got this locally this morning instead. I was afraid I wouldn't like it when I first saw the ad but I really like it. And it was cheap. So it's a win-win.

 

[Curtis P]

Hey were in Canada are you?

Very slick build so far, looks the part

 

[TROYCO]

Hey were in Canada are you?

Very slick build so far, looks the part

Thanks. I'm in Oshawa, not far from you it looks like.

 

[Curtis P]

Not far at all. We will have to.meet up.this season for a ride

 

[TROYCO]

As soon as she's done for sure.

 

[TROYCO]

I'm planning to restore as many parts as possible, so in that spirit, I tore apart the hand controls as many of the original labels were long worn away. I sprayed 4 coats of black and let it cure for a week. And today a package from YAMBITS with new labels came in the mail. Sorry I don't have any before pics. I'm bad at taking pics and just started doing it the other day.

After this, I plan to shoot on some clear to better protect the labels and clean all the contacts up for reassembly. More to follow.

 

[TROYCO]

Also refurbished the gauge cluster with new dampers and rubber pieces, sandblasted and painted the bracket, and polished the housings. The only thing I don't have is a good housing for the dummy lights, but that will come soon enough hopefully.

 

[h3llb3nt1]

Those look brand new. Nice work

 

[TROYCO]

As many of you who live in the Great White North know, painting in the winter sucks. But it CAN be done. I set up a radiant heater I bought from Princess Auto out in my shed and I hang my parts in front of it to warm them up prior to painting, and also to help cure the paint. In between coats I submerge my spray can in warm water to keep it at an optimal temperature for painting. While some of you who have proper painting setups may cringe, it works well for me.

Here's my hand controls after 5 coats of clear. The pics don't do them justice, but I'm satisfied with the results.

 

[TROYCO]

Not much to report, but some progress nonetheless. Swapped out the front forks and rear wheel to the cafe frame, as well as mounted up my new clubman bars. Threw the tank and seat pan back on for mock-up purposes. I can see how it will finally look and I think it works. Also, nice to finally have the chassis rolling.

 

[bcthomas]

Really like the body work choice....what's the paint scheme plan?

 

[TROYCO]

Thanks. I'm going with a black and gold paint scheme. Got a few ideas in mind, but nothing concrete yet.

 

[5twins]

Would you be so kind as to document the details involved in mounting that GS450 tank? The XS750 triple tank is a popular cafe choice and it's mounting on the 650 is pretty well documented but I don't think I've see much about how to adapt this Suzuki tank.

 

[TROYCO]

I would. I have had a hard time finding info as well. I have a few ideas but not sure what I'm going with. I think I might try using the same mounting style as the xs tank.

 

[TROYCO]

Alright gang, here's the latest. I assembled all the parts of the hand controls together and installed them on the bars to see how they fit, and I like the way they fit. I plan on installing the engine in the frame to run it for a bit before I tear it all apart again and begin work to the frame. Hopefully the engine runs without issues.

Also, I've searched around for an idiot light bezel and have had no luck finding anything I could use that looked better than what I had already, and when I tried to make the original look better it actually turned out worse. Here's what it looked like before I ruined it:

So earlier in the evening while I was looking for some other stuff, I ran into this bezel in a box of junk I had hidden away, (looks like it's from a Honda) and to me it looked like a pretty close fit. I need to trim the bracket some and wire the Yamaha pigtail to the end of the harness, but I think after I clean it up some it'll look pretty slick. Here it is mocked up with the gauges. Any thoughts?

 

[scott s]

Great build. Nice attention to detail.

I'm always on the fence about that style of seat. I want to like it, but it has to match the bike/build. You nailed it with the GS tank. Looking forward to seeing how it turns out. Maybe match the paint on the tank and keep it red and black?

 

[weekendrider]

Damn now I'm gonna have to look for a new idiot light cause I like that one better than the stock unit.

 

[TROYCO]

So guess what? Couldn't get the engine running, so out it came. On the plus side, I'm getting very good at tearing it out.

Did a compression test, had 110 psi on the left side, but only could muster 55 on the right. Did a leakdown test and found there to be an issue with the valves. At least I can get a better look at things.

So far I see no unusual signs or any significant wear. I know the jugs were done a few years back but I was pleasantly surprised to find the tensioner and front cam chain guide are in decent shape. At least I think so. Any thoughts? Also, how do the cylinders look? I see some signs of wear but still plenty of crosshatch and I can't feel any noticeable scoring. I feel comfortable leaving it.