My Royal Enfield Cafe Racer project.

[pyro139]

sweeeeeeeeeeeeeeeeeeeeeeeeeeeeeeet

i have a sugestion for what you wanted do to a tax disc.
EL cable its the neon light up wire they use for lighting up computer cases, not sure if there a market for computer modding over there, if there is then you should be able get it easy, comes with relay and every thing you need, has a 12 input and draws 1.5 at under a amp so should have no prob, just wrap it around inside of tax disc and mount the relay on bike frame out of sight
heres one that actualy uses batteries so does run off bike at all
http://www.glowproducts.com/batteryoperated/elwire/

[Canuck Plumber]

too bad it doesnt come any shorter... kinda cool...

[Gordon]

@pyro139: Great suggestion. Will look around for them here.

Will post the pics tomorrow.

Here they are:

The footpeg has been rotated and lowered, to avoid the brake linkage. The current position of the footpeg is quite comfortable.

(http://img441.imageshack.us/img441/2509/rs1zb8.jpg)

The footpeg is now in the way of the side stand. Very difficult to access it. When you're on the bike, its impossible.

(http://img182.imageshack.us/img182/6096/rs2ml2.jpg)

What is this part called?! Will go hunting for it tomorrow. Have another idea in mind if I don't get it.

(http://img293.imageshack.us/img293/7292/linkws8.jpg)

[Tim]

Whatever its called, they're easy to find.  Much much easier than the equivalent on the brake side.  I have one around here I can send to you.   Would just need an address and a few bucks for postage.  Might take a while to get there unless its air-mailed.

[Gordon]

Thank you very much for the help, Tintin. Since its easily available there, could you please check what its called and what size would I need?! Based on that my search will become much easier. If I do not get them here, then I could consider getting them from you.

I tried googling a bit, and found this name "Pinch bolt and nut". Don't really know if its the right name.

[Gordon]

Yes, finally I found out what its called!!! Its called a "Gear Lever Cam". Found some that fit the Enfield. So will have cut and weld it to the Honda rearsets to use them! Will take some time though for rearsets.

And for the brake too, I found a brake lever from another "down-to-earth" motorcycle. Will have to try it on.

[pyro139]

Thank you very much for the help, Tintin. Since its easily available there, could you please check what its called and what size would I need?! Based on that my search will become much easier. If I do not get them here, then I could consider getting them from you.

I tried googling a bit, and found this name "Pinch bolt and nut". Don't really know if its the right name.

in the higjlighted area of last pic the nut and bolt going thru the part is the pinch bolt and nut.

[pyro139]

Yes, finally I found out what its called!!! Its called a "Gear Lever Cam". Found some that fit the Enfield. So will have cut and weld it to the Honda rearsets to use them! Will take some time though for rearsets.

And for the brake too, I found a brake lever from another "down-to-earth" motorcycle. Will have to try it on.

lol makes sence funny none us thaught of it since it conects to the gear level shifter and the shaft coming out of engine that its sitting on is a cam shaft

[Gordon]

lol makes sence funny none us thaught of it since it conects to the gear level shifter and the shaft coming out of engine that its sitting on is a cam shaft

LOL. You bet.

Damn I didn't get time to visit my mechanic for the cam lever and to check whether the levers etc fits properly since I was quite busy in the past couple of days. Was supposed to do it today,  but it had to rain today itself! Hope it doesn't rain tomorrow and then we shall do some testing

[Gordon]

If I don't find that damned cam today, I'll cut the current gear lever and weld its cam to the new linkage!

[Gordon]

Unfortunately the rearsets are going to be delayed. Probably until we finish the next modification on the list, i.e.,

The Cowl!

Have taken an estimate from the fabricator, but he's charging a bomb for it. So we've decided to make the stuff on our own. Lets see how things turn out. Would look something like the below photoshopped pic. The new name will be stuck on either sides of this cowl. The cowl is going to be a removable/detachable one. Not sure how it'll be done, but we're gonna do it. The cowl work would be starting today hopefully. Will post pics as we progress. Suggestions are welcome, specially on mounting/removing/locking the cowl:

[c]

Unfortunately the rearsets are going to be delayed. Probably until we finish the next modification on the list, i.e.,

The Cowl!

Have taken an estimate from the fabricator, but he's charging a bomb for it. So we've decided to make the stuff on our own. Lets see how things turn out. Would look something like the below photoshopped pic. The new name will be stuck on either sides of this cowl. The cowl is going to be a removable/detachable one. Not sure how it'll be done, but we're gonna do it. The cowl work would be starting today hopefully. Will post pics as we progress. Suggestions are welcome, specially on mounting/removing/locking the cowl:

Nice work so far on the Enfield. It's a beauty.
Before people run off and start sending you shift arms (the splined part that rotates on the gear shifting shaft) get a measurement on the diameter and count the number of splines.

When mocking up  controls I start with foamcore or card board for the plates and flat stock.
Use steel rod for the linkages.  This way you can catch any binding problems and dial in the shapes of the parts so they have a sympathy to the surrounding forms. When you are changing these around be aware of ground clearance, the kickstarter and shifter movement.
You'll also want ball end or heim joint linkages for mating the plates to the rods. The bent rod captured through the hole will wear quickly and shift poorly. If its a bit difficult or expensive to have a rod bent and threaded a strait linkage of threaded rod could be used. It looks crap but It'll get the job done.

For your sidestand problem have a .25 dia steel rod welded perpendicular on to the arm so you can catch it with your foot, mind the clearance you'll need for upshifting. Have a knob welded onto the arm or bend it over so it doesn't become a sharp penetrator if it falls on your ankle. If this short arm had a graceful arc it could have form and function!

Alloy would be a nice thing for the seat but may be expensive. You could hack apart a gas tank for a cowl or if you have any talent you could make a form, take a mold and fab up a fiberglass shell. A few steel or aluminum brackets that you could tap into or use dzus fasteners would work well to join the shell to the frame. If you do end up with alloy consider rubbber mounting it to prevent cracking.

Check out www.mcmaster.com for all manner of fasteners. Looking through here will give you some ideas.

c

ps - ditch the crash bars and minimize the rear fender so it won't need the awkward looking support bracket.

[Gordon]

Had noticed this while installing the Goldstar silencer. There is a VERY VERY SMALL gap between the bend pipe and the Goldstar silencer.
Problem?!

[Ease]

No, not really - mine had an isolater in there (just a bit of rubber) to keep it all tight.

Any leaks?

[Gordon]

I can feel some light gases exiting from there when I keep my finger near the gap. Else I don't find ANY change in the sound or in performance. I was just worried, since I've heard that exhaust leaks are too dangerous for valves.