1983 Yamaha XV920 Cafe Racer

Hello all!

It's been a while while I've been building this one... its already described in details on my blog (its in polish... www.wheelandsteel.com) , however I will try to post here some more details. So - let me start from the beginning:

1. On summer 2016 I bought really nasty XV920 Virago - it was really a piece of shit... just painted before selling, so it looks good on photos, but it was a rubbish....





2. I started disassembling the bike and cleaning small parts





3. Next step was to build a "mockup" - do all the welding and most important body work



4. Total disassembling and painting





5. Spoke wheels ready:



6. All small parts segregated and ready to be replaced:


7. Engine painted and assembled again




8. And now ... I am trying to make it all fit together again ;-)






I will update this thread on weekly basis, so stay tuned

No need to convince me - I'm in ;D

I'm on board.

Looks Great! Really like all the attention to detail on this build. Keep up the good work.

What is the cylinder mounted on the front frame mount? I thought it was a coil at first glance but I see it's not! Wicked build so far, insane track of the little details.

jgyuen said:

What is the cylinder mounted on the front frame mount? I thought it was a coil at first glance but I see it's not! Wicked build so far, insane track of the little details.

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Do you mean valve mixture control? no. 11 here:

Working with a swingarm I noticed problems with bevel gear - it worked really hard. I needed to replace bearings, also bought another used bevel gear and used some parts from it. In the end - I have on complete and working nicely.






Also - the previous owner made some changes to swingarm bearings - as he probably was missing bearings, he used some metal sleeves instead and custom made axis. It was working badly, also he made a bigger hole in swingarm to fit the bigger axis... so when I replaced all elements with original bearings, it appeared that I need to make another custom axis to fir the bigger hole in the swingarm. Here it is:

Wheel&Steel said:

Do you mean valve mixture control? no. 11 here:

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Ah, didn't realize the 920s had a MCV!

Rear wheel is on place finally! And it fits nicely

1. First of all - rear swing arm axis - as I wrote before I needed to make a new one. Here it is.



2. Next I fitted all rear parts, all went well. Just some nervous about fitting the rear wheel as its a custom spoke wheel made with XV 535 hub... but it fitted almost plug&play. As the hub is a bit wider then the original one, I need to make some mods to wheel axis - its a bit wider in the end and I need to make this part a bit shorter, so that the axis will go deeper into hob and will come out on the other side. Its a matter of about 15 mm max. Will take care of it in next days.

And here it is:

Sir,thats one damn sexy build.

K&N air filter in place. Needed to use original mounting parts, all fits perfect and you don't see these plastic elements, all is hidden.

Nice Job on the filter, I shall like to steal this idea. What K&N number is it? I just googled and it looks like you used the one that fits the bike on K&N site, that makes sense.

Also I assume you are going to either paint the bolts black or get new black ones?

Maritime said:

Nice Job on the filter, I shall like to steal this idea. What K&N number is it? I just googled and it looks like you used the one that fits the bike on K&N site, that makes sense.

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Yes, its dedicated to this model, its K&N YA-1550

Maritime said:

Also I assume you are going to either paint the bolts black or get new black ones?

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get new ones, these are just to test the whole solution

Thanks. It also will fit the model 750 I have so now I know I can mount it the same way you did. Great job so far on this build for sure.

Last weeks I had a lot of work... but you can see the results

Rear swing arm finally assembled




K&N filter on place, needed to "reuse" original plastic box to fit it to the frame:







Front suspension in place:

- aluminum polished, looks good,
- I used some replacement oil bearings.... they needed some "adjustments"... never again replacements if it comes to rubber parts...
- progressive springs in place... I kept distance parts to keep geometry of the bike. lets see how it will work
- front brake clipper in place, but again - replacement bearings low quality... just ordered new ones from Yamaha.
- front wheel fits perfect!
- in the end: frond light, clip-ons, tank - this made a big difference








Still need to do the following

- engine covers - polishing, will be ready next week,
- accessories to be places on clip-ons
- replace some small parts I missed
- rear wheel needs some care - when I screw it tightly, its blocked. Something there is not right, need to see whats wrong with the new hub
- electricity.... this will be a nightmare
- start the engine and ride!!!

Update

Mirrors and controls in place - nice feeling to grab it







Engine covers polished.





Had some problems with rear hub and fitting it to bevel gear. The hub I have is smaller than original from XV 920 (mine comes from 535 or 250, not sure right now). The size itself is not a problem, but because of that it is a bit shorter and gets blocked by bevel gear screws. However - one small gasket helped to get more distance. All works perfect now.

I'm in.

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