Yamaha XS900 Cafe Project "SHAFTY"

[pugeyed]

Re: new project yam xs850


well headers turned up and they are complete garbage, rotten in 3-4 places so they are going back!


this week have been working on my seat/tail section and front mudguard.


cut down the sides of the seat so it matches the bottom line of the tank and rubbed the cone down to bare fibreglass and gave it a coat of primer, still needs lots more work yet.

chopped the sides off the front mudguard and took off id say 12-14 layers of paint, right back to original fibreglass, this took about 7 hours of sanding off and on so doesnt look like much work but hands are sore now lol.
still needs chopping to size still a bit long.

parts arrived from the netherlands , new fork drain screws to go in my polished legs, and new bottom fork bolts.


here is what the whole lot together looks like

still need to fill with oil and am waiting for some stainless fork caps to be made from a chap in scotland.


once i get my refund from my crap headers i can buy a new front tyre and mount the front wheel. 2thumbs

 

[pugeyed]

Re: new project yam xs850


well tonight's episodue looks at the wiring loom.
x2 looms came with the bike 1 very good and 1 that looked like it had been attacked with a chain saw.


so i started stripping the old tired loom tape off and retaping so the loom kept its original shape


have only found x2 repairs in the whole loom so looking good.

here is the pile of old stuff i took off.

and found some nice woven stuff to go over the straight bits.

next thing to do is put it on the bike and work out which bits need extending, battery terminals for one etc.

 

[Juggernaut]

Re: new project yam xs850

You should check out the yam triples site on a how to remove the reserve lighting unit. It will cut 6 wires out of the loom and make things a little easier.

 

[pugeyed]

Re: new project yam xs850

cheers jugg
will deffo be doing this.
i have some odd wires that need sorting out


http://www.yamaha-triples.org/forums/thread-view.asp?tid=3538&posts=1&start=1

 

[pugeyed]

Re: new project yam xs850

jugg, question about wiring, can i just trace back the wires from the reserve lighting unit and disconnect them from the ends of the multi plugs?
ie just take those wires out as they will no longer be needed.
x2 are easy as they are spliced into other wires but another x2 go to multi block connectors.
one goes to the rear light area but not sure what its for its a light green one.
Thanks
Mark.

 

[Juggernaut]

Re: new project yam xs850

Double check a schematic and get familiar with the wires. I had a difficult time removing the them from the multiplugs and just cut them off flush with the connector. I believe the light green wire is for the headlight indicator lamp on the dash.

 

[jay_kent]

Re: new project yam xs850

Man you move fast on a project, as for the gussets, I say add them but do something to them so it's not just flat pieces of metal in there. put a curve on the outside edge or some speedholes.

Great work on the front end.

 

[pugeyed]

Re: new project yam xs850

thanks man thats a nice comment!
i try to keep moving even if its just something small.
good idea about the holes that would look awesome.

 

[DreadRock]

Re: new project yam xs850

pug just to help keep your mind moving on gussets this is what i did .....

 

[pugeyed]

Re: new project yam xs850

cheers dreadrock, they are really nice matey!



clipons turned up today, very happy with them, quality is good, hope they stand up to the test!
here is a pic

top yoke is just placed on

 

[Cornish Pixie]

Re: new project yam xs850

Nice lookin' work there as usual.

Were the clip on's a bargain? I'm looking for some nice 35mm ones for the 650

 

[pugeyed]

Re: new project yam xs850

yeah i think so mark these are them.


http://www.ebay.co.uk/itm/35mm-CNC-Clip-Handle-Bars-1-pair-Black-/260848367744?_trksid=p4340.m444&_trkparms=algo%3DCRX%26its%3DC%252BS%26itu%3DSI%252BUA%252BLM%252BLA%26otn%3D20%26ps%3D63%26clkid%3D3243381270684269577

 

[Cornish Pixie]

Re: new project yam xs850

What was delivery like from Hong Kong? Was their any duty payable on them? (sorry so many questions!) I've been looking at some italian made ones but they are around £160, which feels like to much money.

 

[pugeyed]

Re: new project yam xs850

bought them on the 21/9/2011 came today, dont know how many days that is lol.
no duty as marked as a gift.
seem good quality, everything does up tight.

 

[Cornish Pixie]

Re: new project yam xs850

Around two weeks, thats not so bad considering the distance they have got to come and cost saving compared to buying in the UK.

I'm going to have a look for some at the Stafford show next weekend, but I can't imagine their will be any that cheap knocking about.

 

[pugeyed]

Re: new project yam xs850


cheers madsod added to the ebay list lol.


havent done much to it lately, been getting the swingarm ready for powder, which means making blanking plates for pretty much every hole in it.


put my fork oil in 2nite and put the top caps on.
chap in scotland has finished my stainless fork leg caps they should come next week.


ordered some bolts to hold the caliper brackets onto the forks.


hoping to get my refund for the crappy exhaust i bought soon so i can buy a front tyre for it and put the front wheel in.


having some custom stainless brake lines made in the states so that should be good.


bidding on some NOS outer valve springs for the engine as you can no longer get them and they will probably need changing when i pull the engine apart.


these are the headers i will probably buy as they are the cheapest i have seen and are stainless.
http://www.bitzforbikes.co.uk/Downpipes.-ref-11085-773-443-36.html

 

[pugeyed]

Re: Yamaha XS850 Cafe Project "SHAFTY"


so not much to show for the last week, still working on the wiring loom, fitted a new fusebox as the old one was well past its best.
got my refund from my crap exhaust so 2nite i bought the front tyre, which means i can put the front wheel in.Dismantled my fuel taps at the weekend and cleaned them out using the ultrasonic, need to do a well known mod on them as they dont have an off position so leak fuel as they get older.
dont think i will be using the front mudguard now (after all that work!) seen this one which i like better.
http://www.ebay.co.uk/itm/270829157570?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_500wt_1202
I won the outer valve springs on ebay for a bargain price , and have started to dismantle the engine, took the sump off and cleaned that out along with the oil pump strainer.

 

[Stankflapper]

Re: Yamaha XS850 Cafe Project "SHAFTY"

Yes, I to vote you first on your application and great work, it is all coming together nicely. Dont you hate having to wait for outside sources to get their shit together!!! It is the only thing that pisses me off on a build and is out of my control.

 

[pugeyed]

Re: Yamaha XS850 Cafe Project "SHAFTY"


cheers stankflapper


another small update, fork leg caps turned up today from Yantosh.
fitted a treat which is always nice, wanted stainless but they look ok in alloy, certainly weigh alot less.

and bolts for caliper carriers as well.

and finished cleaning out the sump , god i hate old gaskets, they just take forever to remove....

oh this is the tyre i ordered, still need the rear but that will have to wait.
http://www.ebay.co.uk/itm/350496241480?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649#ht_6576wt_952

 

[Juggernaut]

Re: Yamaha XS850 Cafe Project "SHAFTY"

I have a set of those on my xs750. They are nice new but mine developed flat spots b/c the bike was sitting in one place for a long while (4 months) without being moved. They also get a lot of good reviews. You should have the shouldered rims and shouldn't need an inner tube. If not those are also compatible with tubes.

Everything is looking great. DON"T rush putting is back together. I scratched a few parts installing them too quickly.