The BOSS - Cafe racer build

[JvZ]

Looks great. You have given me some great ideas for my 850 rebuild, thanks. How hard was it to paint the engine?

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.

[wally]

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.

[JvZ]

£15, I pick it up tomorrow.

[JvZ]

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?

[The Jed]

i don't have your answer but am also interested to know......

[JvZ]

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?

[The Jed]

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).

[JvZ]

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

[JvZ]

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.

[JvZ]

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?

[Agemax]

it is possible i think, if you already have the crankcases ready to accept the kickstart assembly. some do some dont but i dont know which models.
you will obviously need to get a complete kickstart assembly and a clutch cover to accept it

[JvZ]

Thanks, I suppose I will just have to wait until I take the engines apart and have a look!

[JvZ]

Yet another

Okay then. So I bought 2 spare engines because they were cheap on eBay. Well, I have taken it a step further this time. I Couldn't resist this at just £150

alli know is that is is a gs550 but no idea of age model etc. apparently it is all there.

I originally though I would buy it to cheer up a mate who has been quite down for a few months. Now I feel like a real bastard because I really want to keep it for myself as my next project. I was thinking a blue and white scrambler!

[JvZ]

It arrived home! 3 hours later

[JvZ]

Enough looking into the future

Back to "the Boss"

I got the first coat of colour down. I will colour sand and put another coat on tomorrow and hopefully add the decals and black edgings over the weekend.

If all goes according to plan it will get the clear coat next week.







The undersides of the tank and tail will be black.