1982 650E Rolling Cafe Build.

[DrunkenChekhov]

CURRENT STATE:

Well, I started with this:

And so far I'm at this: (carb teardown/soak/rebuild, euro bars, cafe tail)

But soon I will be adding this:

As of now the plan is:
X - New chain/sprockets (spent $120)
X - New front and rear rubber (spend $150)
X - SS brake lines for the front (spent $90)
X - K&N Air Filters (I'm thinking the double ones, not pods) (spent $70)
X - Dynojet Stage 3 (spent $100)
X - All Balls bearings custom made to mount the front end (free)
X - Take care of all the loose ends on the front end swap (steering stops, headlight ears, ignition mounting, etc) (spent $25)
X - Nix passenger pegs/stock pegs and fab up some rear sets (spent $62)
X - New tank off something a little more sporty (some kind of E model) (spent $64)
X - New rear springs to hopefully firm up and raise the rear (spent $90)
X - 4-1 Header if I can find one for a 650 thats not a ****ty mac (spent $300 on BUB)
- Seat pad (est $40)
X - Relocate battery and electronics (free)
- Eventually an electronic speedo and tach (est $200)


X = Done.
/ = Here but not but on.
M = In the mail.


So as you can see, I've got a long road ahead, but as of yet, the bike hasn't been down for any more than 3 consecutive days, and I hope to keep it that way throughout the whole build. This isn't gonna be a high dollar build, but I'll try my best to make it a good quality build, one that I will enjoy riding for years to come.

Lemme know what you think.


And just for kicks, heres what I drive while the bikes down:

 

[Flyboy]

Wow, what a difference already, just with the seat and the bars, I love that front end, that is going to trasform her into another bike altogether.
Following with interest

 

[GS650E_81]

I like the cafe tail. Is that a custom fabrication, or did you buy it someplace?

 

[Guest]

Nice! Looking better already

 

[DrunkenChekhov]

I got it from Roccitycafe, great quality glass. I cut a piece of plywood out to match the shape of the seat to go between the seat and the frame.


Thanks for the interest guys, I'll get this this moving in a jiffy.

 

[Tim Tom]

Your gonna add a box of Keystone Light to it?!?

I kid. You hooked my interest with end few pics. You planning on doing a swing arm swap to match? Maybe an aluminum box unit? I think it would look loads better than the stocker and then you could run a matching wider new wheel.

Cool project. Good Luck.

 

[makenzie71]

haha there's two kinds of redneck cheese!

If it were me and I was wanting an actual "cafe" bike out of it I would get some modest clubmans, drop the front a couple inches in the triples, and get a set of shocks maybe an inch longer.

 

[DrunkenChekhov]

Anyone know if any other size GS exhaust will fit the 650? The only ones I can find are MAC's, and I'd really rather have a Kerker or V&H or even Basani if I can find one.


One last thing, how wide of a rear tire can I fit safely on the stock rear rim?\\


Thanks guys.

 

[DrunkenChekhov]

Well, chain and sprockets are on (went 3 up in the rear since I don't ride highway). And some new shocks, rear sets, and air filters are in the mail. Next up are the bearings and brake lines to get the front end on... Very excited.

 

[DrunkenChekhov]

Put the new rear shocks on the back. They're just knock offs, but from the reviews I've read they seem to be okay, plus apparently they're made by Progressive. Don't know how true that'll be. Nonetheless, they'll be better than the stockers no matter what. You can also see my new sprocket/chain!


Old.

New on right side.

(little fun with the setting sun)

Everything went great on the right side, so I moved to the left. And then, **** hit the fan.

Unfortunately, this happened...

So, as of now I'm thinking I'll get a thread file, and, as there's enough threads to thread a nut on about 3/4 way, I'm thinking of either tightening a nut on all the way and drill a hole through the nut and the bolt and cotter pin it or put a self-locking/nylon nut on backwards to the nylons are towards the inside. What do y'all think?

 

[Flyboy]

Ahhrrr....damn rotten luck there, no big deal though, Jennifer has the same problem, cut it off, drill through and fit a bolt from the inside, mine has been like that for years with no problem.

 

[DrunkenChekhov]

What welds did you cut to slide the stud out?

 

[Flyboy]

I didn't cut any welds, I just cut what remained of the stud off flush.

If you look at the pic below, you will see,I cut the stud off where I have marked in red, the part that is the same thickness as the eye of the shock, then drilled through, and used a bolt the same thickness as the old stud, that fits into the eye of the shock, put an acorn nut on and no one will be able to tell the difference.
You can weld the head of the bolt to the frame on the inside to create a permanent fixture if you like, I did not bother, once the shock and the nut are on and tightened, it's going nowhere.
Will get some pics of it if you want.

 

[salty_monk]

Should be a 2.5" wheel so 130 is your max. I've seen a 140/80 mounted but it looked pinched.

 

[BigD_83]

Anyone know if any other size GS exhaust will fit the 650? The only ones I can find are MAC's, and I'd really rather have a Kerker or V&H or even Basani if I can find one.


One last thing, how wide of a rear tire can I fit safely on the stock rear rim?\\


Thanks guys.

I have a 130 on the back of my '83 650, and although it sits fine width-wise, it has added quite bit of height profile to the tire, so there is definitely some pinching even at that width. IF I could've found one at the price point I was looking for, I would've gone with a 120 again

 

[DrunkenChekhov]

My front tire is a 120 too. Is there any harm/handling drawbacks from using the same width tire front and back?

 

[DrunkenChekhov]

Parts!

One float, needles, bowl gaskets, and one of my K&N's

Rearsets!

I'm still debating on whether to use the R6 rear master or use my Zuk one...

 

[BigD_83]

What rearsets are those? They look very clean.

 

[DrunkenChekhov]

08 R6. I think I'm going to have to modify the shift lever, as of now the rod will only go over the mounts, and I don't think I'll be able to mount them low enough or get a bent enough rod to make it work. The plan for now is to cut it off the linkage from the top and weld it to the bottom. We'll see how everything works out though.

 

[Big Rich]

Nice project DC. I remember reading something about those shocks before.......I think the pressures weren't high enough? Might be something worth looking into over winter.

Good call on the RocCity seat - Sean makes some quality stuff.