1987 Honda XL 600 R Cafe Racer build - "Honda Cafe Cross"
- Thread starter Ocaspersen
- Start date
two-smoker
I reject your reality, and substitute my own!
Re: 1987 Honda XL 600 R Cafe Racer build
I machined my lower tree to take the factory stem. Easy to find replacement bearings.
That mockup looks awesome. I am jealous!
I machined my lower tree to take the factory stem. Easy to find replacement bearings.
That mockup looks awesome. I am jealous!
1987 Honda XL 600 R Cafe Racer build
Johnu: Read thru your build thread, amazing build!! When you turned down the stem from 35mm to 30mm, could you keep the threads for the nut to lock the bearing? Not the top nut, the one that goes under the top triple...
Johnu: Read thru your build thread, amazing build!! When you turned down the stem from 35mm to 30mm, could you keep the threads for the nut to lock the bearing? Not the top nut, the one that goes under the top triple...
1987 Honda XL 600 R Cafe Racer build
Small update from tonights work
I finally got the two last engine bolts out, and also got the engine out of the frame. The bolts and holes in the frame were very rusty, the previous owner has used the bike several winters... and here the salt the streets like hell in winter :-/
And... the ZX10R front is now adapted!!
I finally decided to use the original XL steering stem, it will be easier with bearings and also the lenght of the stem. I started with cutting of the bottom part of the ZX10R stem, in the lenght of the thicknes of the bottom triple. Put this part in the lathe, opened it up to 26mm to take the original stem. Also opened it up to 28mm in the bottom, 15mm into the part, so that the locking ring on the XL stem would fit. Then I pressed the XL stem into the modified ZX stem bottom, see the picture. From there it was only to put back the original beering on the stem
Then I cut of the top part of the ZX stem, and used 13mm of the part without threads. This was also opened, but to 25mm, and now adapt the top triple to the top of the original stem Put the original top bearing back, the lock nut for he bearing and the top triple with the sleeve. Front end sorted!!
Before I can start cutting the frame to move some tubes and start fitting the rear swingarm, I have to wait for the approval papers from the norwegian DMV. I want that to be in order first ;-)
Ordered som new parts as well.... A 2005 CBR 600 RR exhaust muffler, which goes under the seat. Think that will look nice I want to clean up the handlebars as much as possible also, so ordered an internal throttle handle. Will be some adaption there as well, it is for 1" bars not 7/8", but that will be sorted out ;-)
Until next time :-D
Small update from tonights work
I finally got the two last engine bolts out, and also got the engine out of the frame. The bolts and holes in the frame were very rusty, the previous owner has used the bike several winters... and here the salt the streets like hell in winter :-/
And... the ZX10R front is now adapted!!
I finally decided to use the original XL steering stem, it will be easier with bearings and also the lenght of the stem. I started with cutting of the bottom part of the ZX10R stem, in the lenght of the thicknes of the bottom triple. Put this part in the lathe, opened it up to 26mm to take the original stem. Also opened it up to 28mm in the bottom, 15mm into the part, so that the locking ring on the XL stem would fit. Then I pressed the XL stem into the modified ZX stem bottom, see the picture. From there it was only to put back the original beering on the stem
Then I cut of the top part of the ZX stem, and used 13mm of the part without threads. This was also opened, but to 25mm, and now adapt the top triple to the top of the original stem
Put the original top bearing back, the lock nut for he bearing and the top triple with the sleeve. Front end sorted!!Before I can start cutting the frame to move some tubes and start fitting the rear swingarm, I have to wait for the approval papers from the norwegian DMV. I want that to be in order first ;-)
Ordered som new parts as well.... A 2005 CBR 600 RR exhaust muffler, which goes under the seat. Think that will look nice
I want to clean up the handlebars as much as possible also, so ordered an internal throttle handle. Will be some adaption there as well, it is for 1" bars not 7/8", but that will be sorted out ;-)Until next time :-D
Attachments
1987 Honda XL 600 R Cafe Racer build
Got my approval on the build from the Norwegian DMV thursday last week!!
So tonight, cutting the frame
Ordered a frame loop last week, which arrived by mail today... Perfect timing ;-) Cut the rear of the frame to adapt the loop, and also cut the tubes from the seat-part of the frame down to the bottom of the frame. Welded up the rear loop and grinded the welds down.
Measured the frame between the rear pivot again, and the conclusion for the rear swingarm is that I have to make completly new mounts... The plan is to make excact templates next time, and fabricate new steel mounts to attach to the frame. This results in a bit extended rear end than original, but I think it will look great :-D Do any of you have some good links or pics of making a rear pivot mount for a frame?
Some parts are on the way as well... Got around to order a 2005 CBR 600 RR exhaust to go under the seat. Internal throttle on the way, will clean up the handlebars, and a small LED rear light.
One major issue I'm having is deciding for a head light for this build, really cant make up my mind....
Until next time!!
Got my approval on the build from the Norwegian DMV thursday last week!!
So tonight, cutting the frame
Ordered a frame loop last week, which arrived by mail today... Perfect timing ;-) Cut the rear of the frame to adapt the loop, and also cut the tubes from the seat-part of the frame down to the bottom of the frame. Welded up the rear loop and grinded the welds down.
Measured the frame between the rear pivot again, and the conclusion for the rear swingarm is that I have to make completly new mounts... The plan is to make excact templates next time, and fabricate new steel mounts to attach to the frame. This results in a bit extended rear end than original, but I think it will look great :-D Do any of you have some good links or pics of making a rear pivot mount for a frame?
Some parts are on the way as well... Got around to order a 2005 CBR 600 RR exhaust to go under the seat. Internal throttle on the way, will clean up the handlebars, and a small LED rear light.
One major issue I'm having is deciding for a head light for this build, really cant make up my mind....
Until next time!!
Attachments
Cuba Libre
Been Around the Block
Re: 1987 Honda XL 600 R Cafe Racer build
What is that?
M.
Ocaspersen said:
What is that?
M.
1987 Honda XL 600 R Cafe Racer build
It is a throttle handle which routes the cable inside the handlebar. You have to cut if some if the original handlebarnand replace it with the throttle handle.
It is a throttle handle which routes the cable inside the handlebar. You have to cut if some if the original handlebarnand replace it with the throttle handle.
1987 Honda XL 600 R Cafe Racer build
Yesterdays work is not to visible, but took a picture of the bike mocked up with the CBR 600 RR exhaust. Think it will be quite good looking ;-)
The major work yesterday was cleaning some old tabs on the frame, so that I could measure the frame for making the new rear swing adapter. I have cut some tubes from the seat section down to the frame, also cut the end off and welded in place the rear frame loop.
Next time I hope to get some milling done to make the rear swing adapters, and mabye start fitting them to the frame.
Until next time!
Yesterdays work is not to visible, but took a picture of the bike mocked up with the CBR 600 RR exhaust. Think it will be quite good looking ;-)
The major work yesterday was cleaning some old tabs on the frame, so that I could measure the frame for making the new rear swing adapter. I have cut some tubes from the seat section down to the frame, also cut the end off and welded in place the rear frame loop.
Next time I hope to get some milling done to make the rear swing adapters, and mabye start fitting them to the frame.
Until next time!
Attachments
ILoveThumpers
Everywhere is thumpers!
Re: 1987 Honda XL 600 R Cafe Racer build
A seriously slick little bit of engineering that turns rotational force (twist of the grip) into linear motion inside the handlebar. Think of it as a normal cam and follower arrangement enclosed in your handle.
It's how most of these really sick custom bikes have practically nothing hanging off their bars.
-Deek
Cuba Libre said:
A seriously slick little bit of engineering that turns rotational force (twist of the grip) into linear motion inside the handlebar. Think of it as a normal cam and follower arrangement enclosed in your handle.
It's how most of these really sick custom bikes have practically nothing hanging off their bars.
-Deek
1987 Honda XL 600 R Cafe Racer build
I hope it will run ok when I'm finished... Lucky for me I'm a sunday driver, mabye I won't by bothered by bad driving abilities :-D
I hope it will run ok when I'm finished... Lucky for me I'm a sunday driver, mabye I won't by bothered by bad driving abilities :-D
Re: 1987 Honda XL 600 R Cafe Racer build
Haha yes, no one said that directly to me on my build but it was suggested that I go through all of the geometry thoroughly. I did draw it all up using the dimensions from all of my new parts and it turned out that I did not need to do some of the work I was planning on doing. Measure twice cut once!!
SONICJK said:
Haha yes, no one said that directly to me on my build but it was suggested that I go through all of the geometry thoroughly. I did draw it all up using the dimensions from all of my new parts and it turned out that I did not need to do some of the work I was planning on doing. Measure twice cut once!!
MJPriceisright
Coast to Coast
Re: 1987 Honda XL 600 R Cafe Racer build
good lord this thing is going to be awesome.. gotta love those single sided swingers.
good lord this thing is going to be awesome.. gotta love those single sided swingers.
1987 Honda XL 600 R Cafe Racer build
No big update tonight... Cleaned the rear of the frame, and made templates of cardboard for making the mount for the rear swingarm. I will be using 10mm thick steel, shape it, make a groove about 3-4mm deep which follows the frame and weld it on there... Really look forward to this
There will be some weeks without updates, leaving for 3 weeks vacation on the west coast of USA this saturday :-D 2 of the 3 weeks will by motorcycle, cruisin' around...
Until next time!
No big update tonight... Cleaned the rear of the frame, and made templates of cardboard for making the mount for the rear swingarm. I will be using 10mm thick steel, shape it, make a groove about 3-4mm deep which follows the frame and weld it on there... Really look forward to this
There will be some weeks without updates, leaving for 3 weeks vacation on the west coast of USA this saturday :-D 2 of the 3 weeks will by motorcycle, cruisin' around...
Until next time!
1987 Honda XL 600 R Cafe Racer build
Hi guys!
I will be in the LA area from wednesday until saturday morning, and wonder if someone know of some good parts stores?
I'm looking for a digital speedo, braided brake hoses, brake master and brake/clutch levers. Mabye a headlight as well...
Regards from San Fransisco (until tomorrow)
Hi guys!
I will be in the LA area from wednesday until saturday morning, and wonder if someone know of some good parts stores?
I'm looking for a digital speedo, braided brake hoses, brake master and brake/clutch levers. Mabye a headlight as well...
Regards from San Fransisco (until tomorrow
)
1987 Honda XL 600 R Cafe Racer build
Back from vacation, and got some work done tonight
Started making the brackets for the rear swing, using 8mm steel. Got the shape done, some fine grinding left though... Lined them up and tacked them on the frame to see what it looks like. Think it will be good when they are all done, welded up and painted :-D
Took two pictures of the bike to show the different gastanks. The original one, and a 70's GS one with flip-up gascap....
Which one should I use?
Back from vacation, and got some work done tonight
Started making the brackets for the rear swing, using 8mm steel. Got the shape done, some fine grinding left though... Lined them up and tacked them on the frame to see what it looks like. Think it will be good when they are all done, welded up and painted :-D
Took two pictures of the bike to show the different gastanks. The original one, and a 70's GS one with flip-up gascap....
Which one should I use?
