The $100 Wonder: Cafe build....

scotts

No, the engine/valve covers were polished at a local shop that does polishing and powdercoating. If I remember correctly, I paid $40 for both engine covers and $15 or 20 for all four valve covers. So I have $50-60 in polishing, plus my time and labor for the wheels.

scotts

First coat of primer on and wet sanded (two different colors because tank is in bare-metal primer). Also got the right side engine cover on today and mocked up the exhaust.

scotts · Posted: March 2, 2008, 6:20 pm Post subject: Re: The $100 Wonder: Cafe build....

Had a pretty good weekend working on the bike. Got the exhaust mounted up permanently and fabbed up a stop for the centerstand.
We also mounted the gauges (lower than stock) and got the headlight and front turn signals mounted. With extra special help from PamcoPete, we were able to get all the lights/electrical working and tested.
Here are some pics:

scotts · Posted: March 2, 2008, 6:21 pm Post subject: Re: The $100 Wonder: Cafe build....

Here you can see the lowered headlight.

scotts · Posted: March 2, 2008, 6:22 pm Post subject: Re: The $100 Wonder: Cafe build....

And one of the gauges and how she sits right now. I can't WAIT to get the tank and seat back from the painter and get her running!

scotts

Picked up the seat and tank from the painter today and WOW! am I happy with the results! I had them use the '80 XS850 tank as a guide and gave him "artistic license" after telling him what I wanted. The paint is Spies Hecker black and an '05 Lexus/Toyota graphite grey with a pinch of extra metalflake. The pinstripe is gold. Three coats of black, three of grey and three of clear.
I'm going to let it cure for a few more days and hopefully get it on the bike early next week. Whatta ya think?

Cooltouch

What do I think? Dang!

Best,

ichael

cscarroll · Full Member Joined: Oct 08, 2006 Posts: 112

Very spiffy!

scotts · Posted: March 9, 2008, 7:56 pm Post subject: Re: The $100 Wonder: Cafe build....

SO CLOSE! And yet so far....
Today, my Pop and I hooked up a vacuum gauge and an "IV" bottle and got the bike fired up and adjusted/synched the carbs. It was running pretty darn good and I'd say we've fixed 99% of the leaks. It looks like there may be an O-ring on the starter that "might" need replacing.
We noticed that the headlight wasn't working. I had verified that the wiring and light was good when Pamcopete was here by "tricking" the light to come on. I can still do that, but there's no light on when the bike's running. Maybe something to do with the reserve lighting unit?
Oh well....I wasn't gonna let that stop me from getting it back together and riding it around the block today! We installed the seat and tank...had to fiddle with a couple of fuel leaks around the petcocks....got all that fixed and got the bike running again.
That's when the Mysterious Electrical Sh*t started.
Even though there's a full charge in the battery, I can't get the electric starter to do anything. I tried kicking it over many, many times and I've come to the conclusion that there's a short somewhere, possibly in the on/off switch or in the headlight bucket. When it started cutting off, I noticed that bike rocking the bike or wiggling the wire from the starter switch would help sometime...but eventually, nothing. I'm not getting spark now for some reason.
At any rate, here are some new pics. I still have a couple of minor things to tidy up and have the side covers made, but I think she looks pretty damn sexy! Now....if I can just get her cranked again....

scotts · Posted: March 9, 2008, 7:59 pm Post subject: Re: The $100 Wonder: Cafe build....

More pics.

Finksies · Posted: March 9, 2008, 8:29 pm Post subject: Re: The $100 Wonder: Cafe build....

WOW..........where did u get those velocity stacks from. Awesome job.

pumps · Posted: March 9, 2008, 9:11 pm Post subject: Re: The $100 Wonder: Cafe build....

Looks badass!

Retiredgentleman · Posted: March 9, 2008, 9:24 pm Post subject: Re: The $100 Wonder: Cafe build....

You've got a sweet looking bike there...........good attention to detail. Wiring problems...............follow the wiring diagram and just keep trouble shooting.........you'll find the bad connections.
Where did you buy the exhaust system.........I like the look.

scotts

Thanks for all the compliments, guys!
The velocity stacks came from a "Marine something-or-other"??? They're mentioned elsewhere on this site with a link. I think they're for snowmobiles.
The exhaust is comprised of MikesXS head pipes and Dunstall mufflers off ebay. We had to slightly modify the mounting brackets for the mufflers and fabricate a stop for the centerstand.
I'm sure we'll get the wiring figured out....but I was REALLY hoping to ride it today!

scotts

More pics from today.

pumps

I love it. For me the only think I would change is spoked wheels which I have a thing for. I've looked back to the first picture and it is a complete change. Art on wheels. I like Honda GB500s and yours looks better.And cheaper!

drifter

scotts wrote:

I'm still trying to decide on a paint color. Here's another XS750 tank I have; black with a graphite insert. The insert is reflective and looks cool, I think. My significant other is quick to remind me that I already have a black bike.
I considered silver, but I'm afraid the bike will get a little too "washed out" with the chrome fenders and polished engine cases.
Any suggestions?

If you think you might want to part with that black/graphite tank let me know. I love the look of the Seca tanks, but can't deal with a 4 cylinder bike. I just sold my XJ650 Seca to finance the purchase of my "new" XS650.

Dave

drifter

Did you run the stock headlight on this bike? I am thinking of using the XJ650 Seca 9 inch round headlight on mine. Looks very "Euro" cafe style, and throws out an unbelievable amount of light.

Dave

newxs650 · Full Member Joined: Jul 31, 2006 Posts: 62

hey scotts, if you don't mind me asking. where do you get (buy) the cafe seat from? it looks nice. thanks

scotts

Hey guys...I got the electrical sorted out. I replaced the factory fuse panel with inline fuses, swapped the stator out with one from the parts engine, and installed a rebuilt rotor. Everything works now, BUT....I have an oil leak at the head that I just can't get to quit and a tapping from the cam chain tensioner area, so it looks like the engine is coming out of the frame.
Drifter, email me about the tank: uberkafer @ hotmail.com
The headlight is stock but lowered with aftermarket ears and turnsignals installed.
The seat is from Omars. A little pricy, but EXCELLENT quality and the seat pad was included, so I consider it a real value.

pumps

Drifter, There is a model of Yamaha, can't remember, they say it looks like the light on a locomotive. I think it might be cool. Have you got a picture?

wesleyonoel · Full Member Joined: Oct 02, 2007 Posts: 60

Scotts
I have been admiring your work product and am interested in learning more about the mufflers. You got them from an e-bay site? Dunstall mufflers? How do they sound. I like the appearance as they are reminiscent of the stock mufflers on my '73 TX650 - which sound very nice to me. Are they a direct fit to the stock headpipes?......... And what did you have to do with the center stand for clearance?.......... Lots of questions, I know. Any info you can share will be greatly appreciated.........Thanks................Wes

scotts

Hey Wes...thanks for the kind words. The head pipes are from MikesXS and the mufflers are Dunstall mufflers from ebay. I think they sound great and my Dad says they're not as loud/deep as the Commandos I have on my other XS. They were a direct fit on Mikes pipes.
For the centerstand, we made a bracket/rubber bumper that copies the one that comes with the Commando pipes. It was super easy to do. I'll take some pics soon...my girlfriend has our camera right now and should be home tomorrow.

drifter

pumps wrote:

Drifter, There is a model of Yamaha, can't remember, they say it looks like the light on a locomotive. I think it might be cool. Have you got a picture?

I don't know if this is what you're talking about, but check it and see. It's a 1982 Yamaha XJ650R SECA.
The lens is 8" across. It uses an H-4 bulb.

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Yamaha xs650