Cafe Racer project in Australia

Razar

And I've been doing up the master cylinder.

Razar

Just discovered that I've been leading people astray saying that my clipons came from a yzf250. WRONG!! They are from an FZR250. And very nice billet alloy. YUM

yamaman

Kinda thought they wern't from a dirt bike Razer Wink

Pies...............well at least you ride anXS, so you can't be that bad I suppose! The mighty Tigers should slaughter them this year with our gun recruit! Laughing

pumps

Coming along isn't it?

Razar · Posted: March 7, 2009, 4:26 am Post subject: Re: Cafe Racer project in Australia

I've just been finishing off the engine install. Tappets and covers, manifolds torqueing up the engine mount bolts etc.

Today I made some anti reversion cones. They reduce the dia from 1 3/8" ID, the dia of the port,to 1 1/8"ID (34mm to 28mm). The pipes are made for these to slip into. If I'm not happy, I can just fit some non reducing pieces in their place.

Also waiting on my pamco electronic ignition and coil to arrive from Mike's

Razar

My Pamco arrived. Elegant little critter ain't it? I haven't put it in yet and I'm still a ways off running it.

I went to Sydney for a couple of days. Pew!! My eyes were stinging the whole time.
I did get to go to Deus ex Machina's showroom and check it out. Some really nice bikes, though rather expensive I thought. And the obligatory t-shirts were $50 to $70 for nothing special in the way of quality. Still it was all done with style and creative marketing flair. Good to see realy. Now it's not just the Harley guys who get custom.

Today I'm back in the bush letting my sinuses and my feet recover ( I went with my girlfriend so some shopping was done Rolling Eyes

). I managed to give the controls a final polish up and fit them to the clipons.

Razar

Well. I put the cam shaft in the wrong way round. DOH !! So I've spent most of my time pulling it back down enough to turn it around, and putting it all back together again.

Yesterday and today I've been doing the RH side casing. I cut the support for the kickstart shaft off the cover and welded in a plug and ground it down flush. This may not have been a great idea. It turns out that the quality of the cover casting is not very good. It's full of cavities, and most of them are full of oil. A real bugger to weld. I had to turn the whole area into a molten pool to try and fill the holes and burn out the oil. Did this 3 times and just moved the circle of pits out. So my cover looks a bit rough, especially as it's got marks from the brake pedal hitting it.

I think it will mostly be hidden by the pipes and brake pedal and linkages, so I've put it on the engine and I'll see if I can live with it.

I have a spare, but it would be a lot of work to clean it up.

I also made and fit a blanking plug for the tacho drive hole. (electronic tacho)

pumps

I bought a newer style right case with the sight glass off ebay and it had a little bit of pedal scrape that I was able to sand out. My arm was tired but they did come out eventually.
By the way, that front end looks sharp.

Razar

I haven't done a whole lot on the bike lately. I've been battleing the wet season. We've only had a couple of hours sun in the last 3 weeks and it's rained every day. A bit of minor flooding washed out a hole in my road that I dropped my truck into. Not good. I had to get it dragged out by my neighbours big tractor and now it blows white smoke. I think I may have broken it a little.

The mozzie's and leaches are going off. You need repellent and coils to keep them from eating you alive. It makes it hard working on the bike with the mosquito's biting your ears etc.

I wish the farmers out west would stop praying for rain. It looks like the Rain God's aim is off and we're getting it all. And I've had enough. I think I'm starting to go Troppo.

Having said all that, I have been slowly doing all the finishing touches as I assemble the bike. Making sure everything fits properly, doing spacers etc to make sure. Repolishing etc.

jayel

I predict toe'o'boot burn stains on those purty pipes Smile

Razar · Last edited by Razar on May 9, 2009, 1:07 am; edited 1 time in total

I think I'll be OK with the pipes Jayel. I'm tall and my toes stick out a fare way when I sit on it. And the pipes are stainless so I can clean them easily.

I've been continuing doing the left side. Made an alloy chain guard. Shortened the clutch cable, etc. This is a crook picture, new camera. I'll have to do some adjusting on it.

jayel

it's all looking good tho', think some of the old Nortons ran their headers that way, you'll be the only kid on the block with one, cheers

tito650

nice i see made what i call a torque thruster for your exaust,i run one on my 450r they work good . i like that plug for the tach did u machine a 0 ring groove in that or just silicone it ?

geoff1408 · Posted: May 4, 2009, 2:15 am Post subject: Re: Cafe Racer project in Australia

This one nice looking cafe racer. geoff1408

bryant · Full Member Joined: Apr 01, 2009 Posts: 86 Location: KY

I'm really diggin the machined sidewall look on the rims! I'm a bicycle guy first so this takes me right back to my MTB days. Rest of it looks killer too.

Razar · Posted: May 4, 2009, 8:26 pm Post subject: Re: Cafe Racer project in Australia

Thanks guys. The tacho plug is just fitted with permatex goop.

I've been doing the cafe 3 step again. When I filled it with oil I went to turn it over and pump the oil through the engine. Starter spun but did not engage. I checked out the boards and found the post from Retiredgentleman about the spring on the bendix gear so I drained the oil out and took the exhaust and RH cover off to check it. The shaft wasn't even turning. So off with the exhaust and the LH cover and the plate over the starter gears. Seems like I'd put the spacer on the wrong side of the gears. Embarassed

Remedied that, put it all back together and it now whizzes the engine over.

Now it's back to making progress.

Oh, and thanks Jayel for the May Day best wishes. One day society will be run for the common good intead of the blood sucking elite.Lets have real Democracy for a change!! At least you Yanks have a better chance now with Barack than the previous Bozos Idea

Razar · Posted: May 8, 2009, 3:36 am Post subject: Re: Cafe Racer project in Australia

Finished the gauge mount. Fitted the carbs. Pulled my truck engine apart

Retiredgentleman · Posted: May 8, 2009, 11:19 am Post subject: Re: Cafe Racer project in Australia

Great work, you're very good fabricating parts.

Razar · Posted: May 9, 2009, 12:59 am Post subject: Re: Cafe Racer project in Australia

Thanks RG.

This is what a little water does in a diesel engine.

Retiredgentleman · Posted: May 9, 2009, 1:08 am Post subject: Re: Cafe Racer project in Australia

If anyone has doubts whether a liquid is non-compressable this picture would set them straight Smile

bryant · Full Member Joined: Apr 01, 2009 Posts: 86 Location: KY

my dad used to rebuild flood damaged cars. i've seen lots and lots of rods in that condition!

Razar · Last edited by Razar on May 11, 2009, 2:34 am; edited 1 time in total

This is the mounting bracket for my twinfire coil. Bolts onto the top of the old coil mounting plate. It's a little rough but wtf it will be hidden by the tank.

pumps · Posted: May 10, 2009, 11:59 pm Post subject: Re: Cafe Racer project in Australia

Hey it doesn't look any more rough that the oem one welded to my frame.

Razar · Posted: June 4, 2009, 4:06 am Post subject: Re: Cafe Racer project in Australia

It's been awhile since I've had anything to show. I've been repairing my truck, then we had big floods and I was stranded in town for a week. Not as bad as it sounds as I was at my girlfriends.
I've been working on the electrics, a slow and mind straining process, but I think I've got most of it worked out though not done as yet. The pics (sorry about the quality, I have to get a new camera) are of the board that holds the rectifier (thanks pamcopete for the plan) a 4 fuse holder, and on the back a re55 Bosch regulator and a relay that I've hooked up on the ignition switch to turn on the whole system.
I'm putting a fuse on the rectifier circuit, another on the coil circuit, one for lights etc, and one on the starter solenoid circuit. I may change this a little as I proceed.
I'm soldering all the fittings

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