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The BOSS - Cafe racer build

  • Thread starter Thread starter JvZ
  • Start date Start date
The engine is in.
20130511_093207_zpsb0cb41e9.jpg
.

The clutch, stator and points covers still need a coat of paint

The exhaust is going to require a bit more modification, it is just touching on the rearset.

The head light bracket has already been modded and lowered.

It is starting to look like a bike again!
 
The exhaust is looking good, almost too good to heat wrap!

But oh yes, the heat wrap is going on there

20130512_132310_zpse54a3e8c.jpg


Inspired by Wally.
 
Did loads of body work on the tank to get it in shape, still loads of scratches to take out and detailed finishing before it is ready for a top coat. This was just a rattle can experiment. The colour is not what I was going for, but it is growing on me.

Lots of experimenting still to do, I will try to get a picture of the tank on the bike tomorrow evening.

20130512_181200_zpsf443abc3.jpg
 
JvZ said:
Did loads of body work on the tank to get it in shape, still loads of scratches to take out and detailed finishing before it is ready for a top coat. This was just a rattle can experiment. The colour is not what I was going for, but it is growing on me.

Lots
Click to expand...
 
JvZ said:
Did loads of body work on the tank to get it in shape, still loads of scratches to take out and detailed finishing before it is ready for a top coat. This was just a rattle can experiment. The colour is not what I was going for, but it is growing on me.
Click to expand...


Well, the colour has shown a LOT of scratches and pits to fill, but it looks amazing. I was not a fan of the colour at first but it really looks great, particularly where it is on a little thicker, remember this was just a quick experiment, painted pretty much in the dark! (I have no lights in my garage) I am also really loving the flat finish. So much so that I am not sure that I will even colour sand and clear.

All in all loads of sanding and filling to do, but it will be so worth it!
20130513_120132_zpsac74f055.jpg
 
Last edited:
Bike looks to be coming along very nicely, JvZ. I really like how the top curve of your tail piece forms an arc that matches the lines on the tank. Very graceful.
 
Looks great. You have given me some great ideas for my 850 rebuild, thanks. How hard was it to paint the engine?
 
AJ said:
Bike looks to be coming along very nicely, JvZ. I really like how the top curve of your tail piece forms an arc that matches the lines on the tank. Very graceful.
Click to expand...

Thanks very much, that is a large part of the reason why I used the original tail piece.
 
Hakamisu said:
Looks great. You have given me some great ideas for my 850 rebuild, thanks. How hard was it to paint the engine?
Click to expand...

Thanks very much, it was pretty easy to paint, but the prep was a nightmare. I still need to repaint the casings. There are some deep scratches that I need to sand out or I might use the ones from my spare motor.

I used a self-etching high heat paint over everything the taped the head off and used a wheel paint on the body. Once the paint was dry enough I simply tipped the engine forearm and did the bottom. Really pleased with how it came out.
 
My case had some scrapes in as we'll.

I used some of those 2 part metal epoxy repair kits, filled it in and then sanded it down before painting.

It worked out great and is inexpensive.
 
Kickstart conversion

Kickstart conversion

So I picked up the engine, it is pretty rough, but all I really wanted was the gearbox. The motor turns but has very little compression. The carb boots are in decent shape, but they are the ones for slide carbs so of little value to me, but this engine has all the kickstart bits.

Does anyone know if I can actually convert my electric only motor to also include the kicker (nostalgia reasoning)? If so, is it a straight forward process?
 
Sparks

Sparks

Another question for the gurus, I have an electronic ignition upgrade, and have fitted the green 3 ohm dynamic coils, I also plan to run pods and have a straight through 4 into 1. I haven't done anything to the compression, but should I run iridium plugs or stick with stocks?

I fitted them to my Aprila Shiver 750 a while back and didn't notice any difference. Any thoughts?
 
not a guru, but my personal opinion on that and experience with other vehicles is that iridiums are just a way to spend extra money. if anything I would look at different heat ranges or getting an "R" plug, (B8RES vs. B8ES).
 
Good thing I have a couple of spare engines. This weekend I learned that I have one oversized spark plug and it is a tight, rough fit. Guess I'll be swapping that head out

Still doesn't change the plan though. Still going to get this engine running as is, write up the faults list, then tear down the engine and build one from three
 
Last edited:
One step closer

One step closer

I have been doing a bunch of soldering and wiring so it doesn't look like I've done much but it is genuinely some progress. I don't have any fuel system attached but I got the starter to engage and turn the motor over so it feels like real progress rather than looking like it.
 
Kick starter

Kick starter

I need to sort out a leak from my clutch cover and was thinking of doing the conversion to kickstart at the same time.

Has anyone done this before? Is it even possible from an engine internals point of view?
 
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