Hodaka tank cafe build

[barncat]

May as well document the resurrection of another XS. Started with a '71 frame with a lot of surface rust. After de-tabbing etc... had it blasted with aluminum oxide to save hours of prep work.

Scored a decent Hodaka tank last year at local bike salvage. Welded new tabs for rubber mounting to frame. Used what i believe are later model 35mm forks- had to mod the steering stop. New Chinese shocks on the back suitable for solo riding. Upside down superbike bars in custom welded offset clamps to clear raised fork tubes. Been saving nice set of mags with brand new tires for this project. It's a roller now.

 

[barncat]

Rebuilt motor top end this winter down in FL. New rings/hone, new cam chain, extensive porting including cut down exhaust valve guides, lapped valves, e-start delete and block off kick only. Will rewire from scratch.

I usually build my own exhausts but scored a deal on the 2 into 1 header, and going to try the Chinese knock off can- which is surprisingly well made and a true perf core glasspack race style item. Curious to test its performance.

Plan is to fab a slightly asymmetric 1 into 2 intake and use single 34mm TM flatslide. May welcome some jetting input later as that's going to be a challenge, but a few weeks away...

 

[barncat]

Motor back in frame. Had to scavenge points, advance unit and rod off another old motor, adjust valves, and make a tach block off plug out of delrin.

Will need to modify the rear brake lever to clear the exhaust and also make a short kick up pipe section just ahead of exhaust can.

 

[angus67]

How much did u pay for that knock-off akrapovich can? Link?

 

[barncat]

I recall around 50 bucks... they're on eBay. Jury is out on sound and longevity but they look good. Still several weeks from first start up.

 

[pago cruiser]

That Hodaka tank is assume!
Always wondered why I did not see builds with that classic shape.
If you are interested, there is a guy on UK ebay that sells Yamaha "tuning fork" roundels.

 

[barncat]

Yes, IMO the tank is really well matched to the XS motor proportionally and from same era. Still need to acid rinse and shake with old bolts/screws to derust it internally, then Redkote it.

Tank has two threaded outlets. Both need to be used and clearance above motor is tight. I'm making a couple custom banjo bolts to use with special fuel barb fittings for their low profile. Pics later ...

The Yamaha tuning fork logo is my favorite. Already have two nice ones that will fit perfectly in circular recesses on tank sides.

 

[barncat]

After a brief hiatus, back on the build.

Got the exhaust can mounted with a short kick up mid pipe i made. Spent a couple days on the intake manifold. I seem to have a one in-one out theme going with this bike. Single 34mm TM carb.

Gotta mod the foot controls and then rewire it.

 

[barncat]

Took a month or so off on project but it's now basically done save for adding a small LED tail/brake light, wiring in the regulator, sticking a piece of foam on the seat pan and finding a plain square valve cover instead of the vestigial compression release unit.

Fired on the second kick. After several 1st gear engage/stalls the clutch pack freed up perfectly. Who knows how many years of dormancy... figured I'd have to upgrade the discs anyway but shifts great as is.

Happy to report the $50 knock off perf core exhaust can sounds fantastic. Very deep throaty growl out of the 2-1 header.

Of most interest will be that my custom symmetric 1-2 intake works incredibly well. One kick to prime and starts 2nd kick. A BIG fistful of smooth instantaneous torque on demand with the repurposed flatslide TM34. The used Harley dual output coil and irridium plugs no doubt help along with new cam chain and extensive porting.

The jetting is spot on right out of the gate. 3.0 slide, 7DJ1 needle on 2nd clip, 389 P-6 needle jet (hat tip to Grizld 1 for that suggestion), pilot #30, main jet #190, air screw out 1 1/8.

 

[TwoManyXS1Bs]

...Of most interest will be that my custom symmetric 1-2 intake works incredibly well...

Good to hear, Barncat.
Awaiting ride report...

 

[barncat]

Will be testing further of course but can't get too far afield since it isn't registered.

This is build 15 of various makes, so chassis is already dialed in. Well balanced, fairly sticky tires, minimal weight, good ergonomics. Solid at max speed. Front brake is heavy though and mediocre stopping power... old tech, may upgrade.

The intake/carb setup was well worth the work. Big risk- big reward.

 

[MaxPete]

This looks like a really nice, rideable bike BarnCat - well done!!

Pete

 

[Downeaster]

Love to see/hear a video of that running.

I'm normally not a fan of the Hodaka tanks, but that looks perfect on that bike!

 

[wannabridin]

wow, i LOVE the aesthetics of the "C" shape to the intake and exhaust. I bet that long intake runner adds some oomph down low too!

Can't wait to see/hear more here!!!

 

[racerdave]

I can't imagine that single carb with those log runners can equal 2 properly tuned VM34's?

 

[barncat]

Thanks guys.... I usually build a project, ride for a season to get all the bugs out then sell. Posting here is a good way to keep a record of the process. I'm pretty happy with the vintage/industrial lines of this one. And the tuning fork logos fit the circular tank recesses perfectly.

Racerdave- I've already built 2 other XS's that are recorded on this site, both with dual VM34's. This single intake setup is a real torque monster by comparison, and the flatslide produces an instant hit, as other tuners here have noted. I don't think it's giving away much on the top end. Need more miles of testing.

It developed a runaway idle yesterday afternoon when hot so have to track that down. Half a dozen things that could be...

 

[CoconutPete]

Looks good! I like that exhaust. I'm trying to build something similar with a shortened R1 can and a mystery 2-1.

 

[MaxPete]

Can I ask where you got the tuning fork logo badges?

I've been searching for those....

 

[CoconutPete]

Just noticed your battery. Is it just zip tied to the frame? Is that a small antigravity one?

 

[barncat]

Tuning fork adhesive badges were off eBay, where i source most stuff...

I was going to put the battery behind the seat but instead opted to put it on top of the swingarm. It sits in an aluminum tray with two sheet metal screws holding the tray down, then a foam pad to cushion the battery and a heavy duty zip tie around everything to hold down. Less vibration, lower center of gravity, and cleaner look than up high under a cowl... it's a $25 8AH SLA battery, eBay. Bike is kick only so CCA's not too important.

The runaway idle was just weak advance unit springs. Had a pair of new Mikes springs that are way better than OEM. Fixed.