DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: MORK on Jan 21, 2017, 12:07:00

Title: XV920R - Fat and Low
Post by: MORK on Jan 21, 2017, 12:07:00
Well, finally enough progress has been made that I'm not wasting space on a "look what I plan to do" thread.

Bike backstory - PO bought the bike, slapped on a Hageman subframe and a seat, clipons, a gutted fart can with a Harley tip, and a $20 piece of crap eBay light.

Here she be on the way home from Wyoming to Colorado:

(https://uploads.tapatalk-cdn.com/20170121/d8564c29420b8db56cf141b238094fbd.jpg)

Luckily, I also got most of the original parts, so I unbolted the back half, and put the stock seat, subframe and fender back on to get a feel for the bike.

(https://uploads.tapatalk-cdn.com/20170121/e28dfe08d3a05be64c4b99fc6cb203cd.jpg)

It rode ok, the clipons bashed the tank, and the pipe was the most obnoxious sound I've heard in a long time. I don't think it was rejetted either so it ran less then ideal.

So now for the real work to begin...
Title: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:08:52
Another view of the bike in stock-ish form:

(https://uploads.tapatalk-cdn.com/20170121/f5e240f7aef783827787f048583743ed.jpg)

She rides ok, the seat is ugly, comfy, and heeeeeeaaaaavvvvvvyyyyyy. This whole bike is a pig. The rear brake has a wobble as well, but that will be a non-issue soon enough.

And the booger welds:

(https://uploads.tapatalk-cdn.com/20170121/58eb1578da65d80d628767d070dd23ea.jpg)
Title: Re: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:18:59
Another view of the boogers and top rate engineering put into stacking washers to bolt on the cafe seat:

(https://uploads.tapatalk-cdn.com/20170121/b5ce210c28de1bb8adef4c3625f038a4.jpg)

I'm just happy nothing more was hacked up.
Title: Re: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:23:17
So I know it's been done before, and it's not super original, but the Mojave tank just has the perfect lines for this bike in my opinion. I like the KZ650 tank with that ridge as well, but I'm giving the Benelli a try.

(https://uploads.tapatalk-cdn.com/20170121/788a544b1c1a8dc5b379c78872ff2b64.jpg)

It's one of the India copies, hardly any rust inside, a few wobbles to smooth out, but overall, it should look good after plenty of smoothing and welding here and there.
Title: Re: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:27:41
At this point I got the new Lossa Engineering pipe in. It's a great pipe I must say. I was considering the cone quieter core, but this one is a few inches shorter for a quiet baffled muffler, and the quality is wonderful. When the subframe and rearsets are finished, I have been thinking of kicking up the 2-1 pipe a hair.

It also has a nice etched LE that I like.

(https://uploads.tapatalk-cdn.com/20170121/f23d0ba6965ef76e02d40e6670c9ccf4.jpg)
Title: Re: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:32:20
I discovered that the subframe the PO hacked some mounts on was an early Hageman piece, and I think I might end up using it. Maybe as a nod to made these pigs popular, or just to make things easier. I'm not thrilled about the drilled plates, but when painted black, it might hide the battery nicely and could be unique. If I don't like it, I'll just weld up a tube support.

But for now, I welded up a kicked up frame hoop and ran and ground some beads along the subframe tray spot welds.

(https://uploads.tapatalk-cdn.com/20170121/3b527fef88b84413f4c38eaa28f9a36b.jpg)

It's starting to look like something:

(https://uploads.tapatalk-cdn.com/20170121/d0fc5228d2f53535bd44ae8bdd8bc9a6.jpg)
Title: Re: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:37:39
The start of the really fun parts arrived:

(https://uploads.tapatalk-cdn.com/20170121/c09ba8814ad8b1593be160982f3805ce.jpg)

2005 R6 complete front end. The stem from Cognito Moto is already coming at this point.

I have a CB750 nighthawk rear wheel, brake and cush drive to put on as well. From what I can put together, I will be converting to a 530 chain with an XS650 front sprocket and spacer and I forget the Honda rear sprockets to match. Should look good with a 160 rear and not be too wide to rub or bubble out the tire.
Title: XV920R (insert clever bike name here)
Post by: MORK on Jan 21, 2017, 12:49:10
And this should catch us up to the current state of the build. R6 forks on with new tapered bearings - good lord this thing is low now. I have been checking to see if the 2005 R6 has vastly shorter forks compared to all the GSXR swaps out there, but they seem to be within 5mm of each other, so I think it's just going to be a curb scraper.

(https://uploads.tapatalk-cdn.com/20170121/24dbfebe22b0436badf9a835a7ba8d2c.jpg)

I'm considering a skid plate for the exhaust even. Could look cool to make a mini front cowl skid plate. Hmm...

I'm also reminded how small R6's are, and consequently, how small this is going to feel to me. (Not a small bloke at 6'2" 200lbs) The cockpit feels nice though.

This also solidified using the Mojave tank. The XV920R tank is too ugly and bulky, I think the KZ650 tank will be too wide, but this Benelli is looking like it belongs.

So now the tank is de-rusting what little was in there, and I will be shaping and smoothing it as long as the temps cooperate. The rear wheel is curing in its new coat of aluminum primer and when that's good and ready, I'm thinking gloss black front and rear. Maybe gunmetal to show off the nice matching 5 spokes more...
Title: Re: Low and slow XV920R
Post by: bikeWillem on Jan 21, 2017, 13:34:22
Already some great improvements compared to how you bought it. I'm following!
Title: Re: Low and slow XV920R
Post by: ChroniclyQuickly on Jan 21, 2017, 15:03:09
It's going to be gorgeous. With the modern components, I think the skid plate over the pipe would be a relevant touch.

I have frame sliders and lower case crash bars on both of my bikes and people actually comment on them positively all the time. I'm not sure why but they do add something aesthetically for mine and I suspect they'd look even better on yours with that V motor. You can't beat the functionality either, it's nice to not need new case covers if an oil slick rears its ugly head.


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: Low and slow XV920R
Post by: MORK on Jan 23, 2017, 14:43:52
It's going to be gorgeous. With the modern components, I think the skid plate over the pipe would be a relevant touch.

I have frame sliders and lower case crash bars on both of my bikes and people actually comment on them positively all the time. I'm not sure why but they do add something aesthetically for mine and I suspect they'd look even better on yours with that V motor. You can't beat the functionality either, it's nice to not need new case covers if an oil slick rears its ugly head.

Thanks - not quite the skid plate I have in mind though. This thing actually had some crash bars initially, and they are long removed. More likely an aluminum runner underneath just to protect the pipes and case from curbs and speed bumps.
Title: Re: Low and slow XV920R
Post by: MORK on Jan 23, 2017, 16:32:38
I happen to like painting wheels. Prepping wheels... not so much. But for this bike, I think I'll make an exception.

(https://uploads.tapatalk-cdn.com/20170123/4e858e35ec807dc4cd74c9ff9a6e4ee1.jpg)
Title: Low and slow XV920R
Post by: MORK on Jan 25, 2017, 17:17:04
Running some handling numbers...

2005 R6: (my obvious comparison as this is where the fork is from)

Rake: 24
Trail: 3.4"
Wheelbase: 54.3"

R6 fork swapped XV920R:
Rake: 25
Trail: 3.5"
Wheelbase: 59"

I'm pretty excited about these numbers - obviously a ton more goes into it, but I'm getting excited to get this done and rideable. The rear is going to come down a bit with the new tire and wheel setup, but should only be .5-.75" and I should be just fine with that.

Speaking of tires...

(https://uploads.tapatalk-cdn.com/20170125/48ceaf9cc4713851cbaf7caf75ffffc1.jpg)
Title: Re: XV920R - Fat and Low
Post by: jgyuen on Jan 29, 2017, 01:53:12
Is that the new rear? I wanna see that sucker shoe-horned in there
Title: Re: XV920R - Fat and Low
Post by: MORK on Jan 29, 2017, 22:08:14
Is that the new rear? I wanna see that sucker shoe-horned in there

You and me both. The rear wheel is still curing - should be mounted this week. Shouldn't take much shoe-horning, maybe a bit of spacer trimming, and I believe I have the sprockets all figured out as well for the 530 conversion.
Title: Re: XV920R - Fat and Low
Post by: MORK on Feb 10, 2017, 16:40:06
Wheel and tire clear - picking up conversion spacers this weekend and the new bearings should be here soon...

I have decided against fiberglass, so things are going to get a bit more fun around here...

(https://uploads.tapatalk-cdn.com/20170210/fe24e4ac170c9cf38070e884ecf22588.jpg)
Title: Re: XV920R - Fat and Low
Post by: Kamn on Feb 10, 2017, 17:08:38
I see you are going the aluminum route??
Will this be your first rodeo? Cause that stump looks brand new

Good luck dude
Title: Re: XV920R - Fat and Low
Post by: MORK on Feb 10, 2017, 17:22:16
I see you are going the aluminum route??
Will this be your first rodeo? Cause that stump looks brand new

Good luck dude

Just carved it out today and made a couple test panels. The idea I have rattling around in my head should be simple enough for a first project in hammering one out.
Title: Re: XV920R - Fat and Low
Post by: Kamn on Feb 10, 2017, 17:39:51
And my good luck was sincere just incase it came across as a sarcastic or smart ass-ish
But good job on carving out the stump, do you have other tools to go along with the stump, like an english wheel or some big dollies?
And get ready to sweat like a whore in church during confession.......I started on my tank last weekend, getting the top part hammered out and boy was I sweaty as hell
But I will say this, there is an awesome sense of satisfaction when you start to form out what you have pictured in your head........also be ready to screw up a lot of pieces potentially, so have plenty of material on hand.

What kind of sheet alum did you get?
Title: Re: XV920R - Fat and Low
Post by: kadavenport on Feb 11, 2017, 02:38:40
Best of luck with the aluminum! I'm just got upstairs after a few hours cutting out and bending the bottom and tunnel for my alloy tank. As kamn said, "sweaty".


Sent from my iPhone using DO THE TON (http://r.tapatalk.com/byo?rid=89466)
Title: Re: XV920R - Fat and Low
Post by: MORK on Feb 11, 2017, 12:09:31
I'm actually debating on steel vs aluminum for what I have. I have plenty of sheet steel for practice and i might be needing it to be magnetic for what I have planned.

Right now I would love an English wheel, but to learn the fundamentals first, I'll be making a stationary forming dolly for the planishing and then using the other standard hammers for the rough work.
Title: Re: XV920R - Fat and Low
Post by: Duncn70 on Mar 04, 2017, 18:03:56
What's involved in doing the nighthawk rear wheel swap?  New bearings, spacers, and upgrading to the 530 chain?  I also have a 920r with an '08 R6 front end and can't stand that virago rear wheel.  I already have a nighthawk wheel, brake, and hub.  Any help would be great!  Thanks!
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 13, 2017, 23:03:08
What's involved in doing the nighthawk rear wheel swap?  New bearings, spacers, and upgrading to the 530 chain?  I also have a 920r with an '08 R6 front end and can't stand that virago rear wheel.  I already have a nighthawk wheel, brake, and hub.  Any help would be great!  Thanks!

You pretty much got it, I'm still waiting on the final rear spacer that sits in the cush drive bearing. You also obviously need the new seals but all balls has the right bearings and seals.

You also need to drill out and or replace the drum spacer.

Drilling and tapping the front sprocket will probably be the hardest part. I'm going with an xs650 front sprocket. I think I'm doing 17/36 if I remember right but I'm not sure off hand. I used a couple calculators with the different chain pitch, wheel diameter, and sprocket sizes to get as close to factory as I could. 
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 19, 2017, 19:39:14
Finally found the tank I wanted. I had picked up a Benelli Indian remake turd and was getting so annoyed polishing that piece of crap that I went out and found what I really wanted. It's been done a few times, but I don't care and I really like the lines.

(https://uploads.tapatalk-cdn.com/20170319/9ef1f2ab991c1c92a11ab89bdb2f00d0.jpg)
Title: Re: XV920R - Fat and Low
Post by: Brodie on Mar 19, 2017, 20:13:40
Looks great. The benelli is a very played out on the Virago.

What is the new tank from?
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 19, 2017, 20:24:21
I liked the Benelli but along with the quality issues (I was welding and grinding every leaky seam) it only holds 3gal. It also just felt so narrow.

The new one is from a KZ650SR.
Title: Re: XV920R - Fat and Low
Post by: Kunphushun on Mar 19, 2017, 22:04:23
You guys doing these Virago conversions are just flat amazing!  Well done.  Looking forward to updates!
Title: Re: XV920R - Fat and Low
Post by: jgyuen on Mar 20, 2017, 01:50:27
How much work is going to go into getting that Kz tank to stay put? Centre channel is obviously wide enough
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 20, 2017, 09:49:14
How much work is going to go into getting that Kz tank to stay put? Centre channel is obviously wide enough

Almost wide enough. I need to smush in the tunnel a little. Front mounts look to be pretty good, but I won't know for sure until I set it all the way down. Rear mounts need to be welded up, but those are easy enough.
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 21, 2017, 16:38:03
Tank mounting Tuesday. Not the final hardware and needs a bit of finish sanding, not to mention a better damper, but progress always makes me happy.

(https://uploads.tapatalk-cdn.com/20170321/e90fe4d1d00612ac5c2c1f3a63f4b243.jpg)

(https://uploads.tapatalk-cdn.com/20170321/f143aad2b14d61376e42a8efb0e16068.jpg)
Title: Re: XV920R - Fat and Low
Post by: advCo on Mar 21, 2017, 17:06:21
That tank does have some nice lines. Looks good on there.
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 29, 2017, 17:20:04
Little color teaser...

(https://uploads.tapatalk-cdn.com/20170329/a08f608bd1f8dd092fb6460e4549f8a3.jpg)
Title: Re: XV920R - Fat and Low
Post by: cole.pinnow on Mar 30, 2017, 22:43:52
Finally found the tank I wanted. I had picked up a Benelli Indian remake turd and was getting so annoyed polishing that piece of crap that I went out and found what I really wanted. It's been done a few times, but I don't care and I really like the lines.

(https://uploads.tapatalk-cdn.com/20170319/9ef1f2ab991c1c92a11ab89bdb2f00d0.jpg)

Damn that looks good. I stuck with the Benelli remake and can attest to its issues. Haven't finished fixing them all yet... I really, really wanted a Hageman subframe but couldn't justify the coin. Ended up with a Twigg TT frame - wish I would have just built one myself in the end.
Title: Re: XV920R - Fat and Low
Post by: MORK on Mar 31, 2017, 17:38:36
I like shiny things :)

(https://uploads.tapatalk-cdn.com/20170331/45f7216834533094149fe75e20981f88.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 01, 2017, 16:36:19
Little things on builds make me happy - the original KZ650SR gas cap still functioning and looking nice with a little scuff and clean for example.

(https://uploads.tapatalk-cdn.com/20170401/ec44413dd319e40df590fcd0bfeb236b.jpg)
Title: Re: XV920R - Fat and Low
Post by: nateb on Apr 02, 2017, 10:03:53
 It's looking really nice man


80 cb750
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 11, 2017, 11:27:34
This color is never the same in pictures. Still waiting on spacer, so the chrome headlight surround was addressed. I had picked up a universal emgo bucket after looking at many options to fit the 7" led setup I wanted to use. The brushed surround and black is just what it needed.

Ugh... not looking forward to wiring though.

(https://uploads.tapatalk-cdn.com/20170411/d69f73a4db9800797b3f24019534db87.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 12, 2017, 14:50:25
Running no fenders are cool unless you actually get out and ride. This will also be the only bike in the shed that stops better than it goes. Looking forward to that...

(https://uploads.tapatalk-cdn.com/20170412/12e280608fb84766609fab968eb17f33.jpg)

(https://uploads.tapatalk-cdn.com/20170412/eacba9e42376c9497222ac0fda268db4.jpg)
Title: Re: XV920R - Fat and Low
Post by: JAGspeed on Apr 12, 2017, 21:33:26
Looking good! Diggin the color something you don't see everyday. Looks like it is close to being finished. I'm with you on the fender. Like the look without it, but I've been caught in the rain to many times to run without one. Good luck with the wiring. I use patience and beer.
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 15, 2017, 16:36:54
And she's a roller! First time I have seen the bike outside in the sun since the week I bought it. Good lord it's low.

Current thoughts are a set of CM drop triples, and a matching rear hagon shock for about a 1" ride height raise.

(https://uploads.tapatalk-cdn.com/20170415/6a5c4cc42ff143f8a1e6bb7d8f3c7dfb.jpg)

Now... do I want to drill it for some bars, or keep clipons...
Title: Re: XV920R - Fat and Low
Post by: JAGspeed on Apr 16, 2017, 02:01:11
Current thoughts are a set of CM drop triples, and a matching rear hagon shock for about a 1" ride height raise.

Now... do I want to drill it for some bars, or keep clipons...
You could get an inch up front if you used regular bars because you would not need the top of the fork to clamp the clip-on to and you could slide it down in the triple clamp. If you wanted to keep a clip-on bar find one that clips below the top clamp like a Honda one and has a little bit of a rise to be more comfortable. This will also allow you to slide the forks down some.
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 16, 2017, 22:05:39
True, but that ain't exactly the cleanest way to do it. I think with the cognito drop triples and a clean set of bars, it will be not only more comfortable, but will have a nice clean look.
Title: XV920R - Fat and Low
Post by: MORK on Apr 25, 2017, 18:42:01
Spent the weekend not working on the bike one bit...
(https://uploads.tapatalk-cdn.com/20170425/601bbd0954b30a7ffb1116c1a3164320.jpg)
(https://uploads.tapatalk-cdn.com/20170425/8ec34e309680cf8eb476e8df1426f607.jpg)
But a bunch of parts are on the way!
Title: Re: XV920R - Fat and Low
Post by: MORK on Apr 30, 2017, 17:38:43
More subframe work. Also another reason to lower the forks is that I don't think I have enough clearance from the front fender to the frame. The drop triple, clamps, and bars are in the mail...
(https://uploads.tapatalk-cdn.com/20170430/ed1dfa74ae3a86ca2fc49e3c274d3046.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on May 24, 2017, 19:46:19
MMmmmmm......

(https://uploads.tapatalk-cdn.com/20170524/36d54c0d381daf007a288f1336a02c6c.jpg)
Title: XV920R - Fat and Low
Post by: MORK on May 30, 2017, 13:16:07
Currently cleaning up wiring and waiting on rear shock. Front brake lines came in and still have to order the battery. The bars at 29.25" feel perfect.
(https://uploads.tapatalk-cdn.com/20170530/291f20bdc30a832d4c0bca6724252c57.jpg)

Decided to keep the fuse block and make a bracket for it. Also took almost 2" out of the headlight ears - was out way too far as you can see above.
(https://uploads.tapatalk-cdn.com/20170530/6de9e31f94290dda59dc78c0372648ff.jpg)

The headlight is bright as well!
(https://uploads.tapatalk-cdn.com/20170530/7d8eddb33bddfbb26b97bb77cbbe341c.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 01, 2017, 16:13:10
New lines, F4i master cylinder to lose that ugly reservoir and fresh fluid.
(https://uploads.tapatalk-cdn.com/20170601/e5612c0bee9d22a89346006dabb21bae.jpg)
Title: Re: XV920R - Fat and Low
Post by: YamahaTR1 on Jun 05, 2017, 13:03:40
Nice!
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 15, 2017, 09:45:55
Subframe is in. Antigravity 12 cell, mosfet R/R, and the rest of the wiring like the turn signals and gauge prep gets me back to being a runner.

(https://uploads.tapatalk-cdn.com/20170615/1ea3c7c9dce393a2bda7de7c669b2a8f.jpg)

(https://uploads.tapatalk-cdn.com/20170615/cc948afcf36cc4c3165c552bf2991956.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 16, 2017, 22:00:18
It's the little things nobody will see...

(https://uploads.tapatalk-cdn.com/20170617/8fe52a1750dec7ffed20e5e2cf40fa69.jpg)
Title: Re: XV920R - Fat and Low
Post by: JAGspeed on Jun 17, 2017, 22:52:38
WOW! this bike has turned out really great. Good job on the top clamp, super clean look and totally helped the clearance issue.  Cool little tail light.. What is it off of ?
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 20, 2017, 19:26:27
WOW! this bike has turned out really great. Good job on the top clamp, super clean look and totally helped the clearance issue.  Cool little tail light.. What is it off of ?

Thanks, I'm getting really anxious to get riding it. The rear shock helped just as much and should match up really nicely with the R6 spring rate etc.

The light is from TST Industries originally meant for an FZ-09 with super bright integrated signals etc. it's tough to get a picture as it's brightness overwhelms my camera. I guess almost 90 led's will do that. :)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 20, 2017, 19:41:09
I tried to get a picture of the light on, but it's just too intense for the camera to discern clearly what it looks like in person.

(https://uploads.tapatalk-cdn.com/20170620/9dab9b4df2bef30503b5171eaf913218.jpg)

It also took forever to figure out a signal problem with the wiring that turned out to be all three wires pulled out from the switch. It's now cleaned up, re-soldered and epoxied. Should be good for years.

(https://uploads.tapatalk-cdn.com/20170620/cb56ce88a1d4bf696ed2912f20881a37.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jun 30, 2017, 11:21:21
(https://uploads.tapatalk-cdn.com/20170630/58f6c923c2493c1f5aa719dac9795c3c.jpg)

Closer...
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 06, 2017, 15:08:11
Alright - any gearing experts out there? Im having a 17t front sprocket currently drilled and tapped to match the original sprocket and I'm debating what final ratio I want.

Because of the new rear wheel, I can go as low as a 34 in the rear and running everything through a great gearing calculator (gearingcommander.com) with a 36t rear, I am almost spot on the the factory ratios even working in the difference in wheels and chain pitch.

However one thing I dislike about many Japanese bikes is just how high they always seem to spin, so I'm thinking of going 17/34.

Any downsides with the additional chain and sprocket wear?

Can anyone think of a reason not to drop to a 34 rear with this relatively torquey low revving twin?

Here is where I'm at with the 17/34:
(https://uploads.tapatalk-cdn.com/20170706/e4b59a2b115c642f43d24a673ffd1bb9.png)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 12, 2017, 13:05:31
Sigh. Machinist broke a couple bits and wants to give up drilling the sprocket. It's ok though, in going to try out MikesXS 18 tooth and see if I can make the pre drilled speed holes work.

Also, it's getting close... Antigravity 12 cell, new mosfet R/R and motogadget mlock keyless ignition. This ain't no trailer queen fenderless hard parkin sunny day show Nancy. No sir.

I might have to think of a new name beside fat and low seeing as the effort done to mitigate exactly that...

(https://uploads.tapatalk-cdn.com/20170712/5becdc2c249dc425e4b9d28fbf31cb6e.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 16, 2017, 18:43:22
Didn't like the idea of drilling the part that isn't made anymore and thinning the material to fit the "speed holes" on the MikesXS 18t sprocket. (And I didn't like it was made by emgo...) so here is a successfully drilled and mounted 17t front JT sprocket.

(https://uploads.tapatalk-cdn.com/20170716/9ae2abbe3b7e2f3bf3223dfc3c793514.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 20, 2017, 21:53:58
I'll just put this here for anyone's reference on future builds...

My final spacer measurement to use a CB750 nighthawk rear wheel on a virago XV920R is 22mm drive side and 24mm brake side.

You also need to either drill out the sprocket bearing spacer or machine a new one to fit the 20mm axle.

Other than drilling the center spacer and fitting the appropriate bearings, that's about it. My spacer dimensions are for a 530 chain with the XS650 sprocket up against the retaining washer without an additional spacer.

Pictures later as I'm putting the finishing touches for the chain tonight.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 21, 2017, 01:50:41
She moves.

(https://uploads.tapatalk-cdn.com/20170721/e9d86f342e4f242506160a4e6da49618.jpg)
Title: Re: XV920R - Fat and Low
Post by: danielnordin on Jul 22, 2017, 19:06:18
How did you manage to drill not one, but TWO holes in that sprocket? I'm going for the exact same setup with the nighthawk wheel as you but the front sprocket gives me headaches. Any advice?
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 24, 2017, 12:55:58
How did you manage to drill not one, but TWO holes in that sprocket? I'm going for the exact same setup with the nighthawk wheel as you but the front sprocket gives me headaches. Any advice?

I had picked up a set of cobalt drill bits - found a kit of 6mm - 1.5mm on amazon or something. They actually don't show really any wear after, and I had to use multiple steps.

The first hole the machinist tried and broke a bit so I had a pilot to start and that one cut through fairly easily curling off the metal until the back side and it more or less chipped away at it sending fleck of metal out rather than a nice ribbon.

It took an hour and a half of switching up bit sizes and boring out the smaller holes. I dont want to ever do it again.

Cutting oil, patience, and time are your friend. Once the sprocket started heating up, it seemed to take longer. The 2nd hole took forever compared to the first.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 25, 2017, 13:23:51
Removed some paint on the rear wheel to match the front. I think I made the right choice over all black.

Chain rivet tool arrives today so should be rideable tonight...

(https://uploads.tapatalk-cdn.com/20170725/6a3f4975434867f6629e4f7d56411633.jpg)
Title: Re: XV920R - Fat and Low
Post by: advCo on Jul 25, 2017, 13:52:28
This thing looks great, man. I love the way the turquoise pops against the black. Top notch
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 25, 2017, 19:11:10
Took 'er around the block and filled up the tank. I'll probably back out the preload on the rear and still have a few finishing touches, but oh man... that is a satisfying feeling.

Doesn't feel fat in the slightest anymore. And... there has been considerable effort in making it not low (like every Virago cafe build) I will have to think of a new name.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 26, 2017, 00:05:25
It's raining. I have a freshly completed Virago cafe bike. Let's ride! (Said no one ever...)

(https://uploads.tapatalk-cdn.com/20170726/8d2ec8732391e4294ad169d0450c4c69.jpg)

(https://uploads.tapatalk-cdn.com/20170726/54b9a5fc0736efe93ebe7dd55bfa3666.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 26, 2017, 16:11:41
It had a bit of a stumble on heavy acceleration last night. New AP63's gapped at 0.028 and eliminated all vacuum lines to the mixture controller.

Still some very slight hesitation, but it's almost all gone.

Also a couple of the other pictures from last night.

(https://uploads.tapatalk-cdn.com/20170726/d77becbea05d0c03eac0ab9effa8134c.jpg)

(https://uploads.tapatalk-cdn.com/20170726/40f34ae0463489188f73a85d4d7ddf32.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 27, 2017, 13:50:49
(https://uploads.tapatalk-cdn.com/20170727/4086774f95b80acd8d54b689f733aade.jpg)

This is also one of my favorite garages built by a friend. In a corporate development you take a back alley between a pizza place and an office building, go through the service alley and there is this hidden driveway. Three double doors lead to a full bathroom/shower and kitchen/coffee bar and a back elevator up to the big corner office.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 29, 2017, 12:57:32
Is that a weathered garage door? Hot damn, I better park my recently completed bike next to it and take a picture immediately.

(https://uploads.tapatalk-cdn.com/20170729/bc45a5b88508b7a813c2712d5086aaca.jpg)
Title: Re: XV920R - Fat and Low
Post by: MORK on Jul 31, 2017, 13:36:54
Broke out my shoe mirrors.

(https://uploads.tapatalk-cdn.com/20170731/f0991a522e260c0e9c039ab0dce8a915.jpg)
Title: Re: XV920R - Fat and Low
Post by: JAGspeed on Jul 31, 2017, 22:56:56
Pics of the bike look great!  How did that 17/34 gearing work out? Trying to figure out what gear to run on mine.
Title: Re: XV920R - Fat and Low
Post by: MORK on Aug 01, 2017, 11:17:25
Pics of the bike look great!  How did that 17/34 gearing work out? Trying to figure out what gear to run on mine.

After mounting everything, I went with 17/36. There isn't quite enough clearance for the 34 in the rear. I already shaved the swingarm enclosed drive mount tabs and the front sprocket housing, and while the chain could fit, any deflection would put it into the case and the swingarm.

17/36 is actually just a hair taller than the factory ratio even with the 17" wheels.

I don't feel that it's spinning all that high at all - if I were commuting on it on the freeway for extended amounts of time, I'd go 18. I might try and see what the clearance is like for an 18/34 if I try and attempt anything like a multi state trip. That could make 75mph highways comfortable I think.
Title: Re: XV920R - Fat and Low
Post by: LazyOx on Aug 04, 2017, 13:57:12
The bike looks sweet, the rims with the metallic edge really complete the package, hope it rides as good as it looks.

Title: Re: XV920R - Fat and Low
Post by: MORK on Aug 10, 2017, 22:19:07
The bike looks sweet, the rims with the metallic edge really complete the package, hope it rides as good as it looks.

Thanks - it rides fantastic. Torquey, really tight feeling, and surprisingly flickable.
Title: Re: XV920R - Fat and Low
Post by: MORK on Aug 22, 2017, 18:58:36
She definitely can take a turn or two.

(https://uploads.tapatalk-cdn.com/20170822/367269406d72fad139db6bcc335ec986.jpg)
Title: Re: XV920R - Fat and Low
Post by: LazyOx on Jan 16, 2018, 12:11:34
MMmmmmm......

(https://uploads.tapatalk-cdn.com/20170524/36d54c0d381daf007a288f1336a02c6c.jpg)
Mork, where did you get the Upper Yoke?
I think I need that for my R6 2011 front end so I can get the nose of my TR1 up.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jan 20, 2018, 00:49:47
Mork, where did you get the Upper Yoke?
I think I need that for my R6 2011 front end so I can get the nose of my TR1 up.

Its from cognito moto. Wonderfully well machined piece. I went with their 1 1/8 bar clamps as well if you are looking for real bars and not clip ons.
Title: Re: XV920R - Fat and Low
Post by: MORK on Jan 20, 2018, 18:00:24
(https://uploads.tapatalk-cdn.com/20180120/906861437e887ae1a1e0ee3649e80881.jpg)

Winter is coming tomorrow and I needed an excuse to keep a nice charge on the battery.

Also, anyone have any particular battery chargers/tenders they like specifically for li-ion?