"CBass" -- Yamaha Virago XV750 Cafe Build (Finished!! Updated with Pics and Vid)

T.Stanley

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Sup Fella's!!

Picked up another project to Cafe. Nothing special here. As with a million others, I was inspired by Gregs Cafes. I love the V-Twin, unique frame design, cruiser-turned-cafe, and especially how narrow these bikes can be. I'm familiar with Honda CB's and Triumphs but none with Yamaha. It'll be a learning curve but this forum is full of great info. This will be my 4th build and excited to finish it so I can ride!!

I wanted to blog the progression of my build. I'm sure I'll run into some issues, and I hope the VTF will lend an hand when needed :usa:

Project is named after my wife's nickname -- "CBass"


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Purchased in November, the day before Thanksgiving for $250 delivered on Craigslist. Came only with a bill of sale but there is a process to get it registered correctly thru CA DMV and CHP. Two days and $106 later, registered under my name :)


Bike was last registered in '96. It was a non runner and was pretty filthy. Missing tank, tach, headlight, and a few other thing I didn't need anyways.








 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build




Went on a buying spree in Dec. I wanted to gather as many parts/goodies while I was tearing down the bike so when it came time to reassemble, I didn't have to wait too long...... 8)


Carb teardown, inspection, and rebuild. Carbs were disgusting. I soaked them in simple green overnight, disassembled everything and soaked again. K&L full rebuild kits were used. Floats height adjusted to 17mm and benched sync'd. No tears in the diaphragms.
















 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build



Right control switch rebuild. Cleaned with electrical cleaner, sanded corrosion off all contact points, and regreased with Honda Dielectric Grease -








 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build



- Removed old subframe, fuse box, horns, fenders, controls.
- Started labeling wires and connectors because I suck at electrical work.
- Test fitted new subframe, seat pan, and battery holder.
- Clean Carbs test fitted (these were a bitch to get on btw).
- Removed front brake calipers, disassembled to get ready for powdercoating. K&L rebuild kit waiting....













 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build




Mailman delivered some parts so I decided to test fit some parts. I'm converting my wheels from stock mags to wire spoke wheels. I heard and read that it's extremely difficult to do...... The one thing I'll advise is to measure, measure, measure and measure. I spent a good hour just making sure my measurements were correct before machining the axle.


- 1978 XS650 36 spoke hub and axle bolt
- New All Balls Bearings and Seal Kit
- Machined down on lathe, 35mm fork clamp width, 15mm OD on left axle boss, 17mm OD on right axle boss. Needed a 2mm spacer on right side.
- Tore down frame from engine for prepping and powdercoating



















 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

deepwaterimports said:
Are you painting the controls/switches at all ? I'm onbord this one for sure.


I purchased a new reproduction swtich for the right controls. I'll have the left control housing either powdercoated in gloss black, or may just paint it although I prefer powdercoating; any competent place will do it for about 10 bucks.
 

CarbsAndCylinders

Careful With That Axe Eugene
Re: "CBass" -- Yamaha Virago XV750 Cafe Build

Congrats, these make nice Cafe's. I would guess that a lot of weight can be removed from them too. I see that you have raised the fork tubes, this will quicken the steering, is there ample clearance to do this and not scrape on the corners?

You soaked the carbs in Simple Green, was this enough to clean out the jets, or did you need to do more?

I'm suscribed!
 

beachcomber

TJ - Beachcomber
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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

So much easier with chain drive !!! ;) Also the front axle mods are minimal with the bottom mount clamp forks. Rear wheel uses the stock TR1 axle with new spacers.

I've got a Grimeca 4LS hub / brakes for mine now [ front ] - and the Grimeca axle is a direct fit - no mods ! What's the chances of that. 8)

 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

CarbsAndCylinders said:
Congrats, these make nice Cafe's. I would guess that a lot of weight can be removed from them too. I see that you have raised the fork tubes, this will quicken the steering, is there ample clearance to do this and not scrape on the corners?

You soaked the carbs in Simple Green, was this enough to clean out the jets, or did you need to do more?

I'm suscribed!

These thing weigh a ton when stock I hope to shed about 50lbs off the bike, if not more. As for the forks, I rebuilt and installed progressive springs on the fronts. They were lowered 2 inches internally with spacers on the damper rod. A few guys over on viragotechforum have lowered stock forks 2 inches with great success. Rears are fitted with a new Progressive spring and will be air adjusted for rebound.

With the carbs, I soaked them in simple green which loosened a lot of crud, then scrubbed everything with a toothbrush. Carb cleaner and compressed air helped with all of the passages.
 

DesmoBro

Busted Nut
Re: "CBass" -- Yamaha Virago XV750 Cafe Build

Who just hit me with a Salt Shaker?

Kick his ass CBass!!!

nice build so far man shed that weight!
 

beachcomber

TJ - Beachcomber
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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

FYI - the steel spoked alloy wheels are much lighter than the OEM swirly wheels.

I just sent a pair of redundant alloys off to a guy who is restoring a TR1 [ ? ]

I had to weigh them for the carriers to quote.

The rear wheel is TWICE the weight of the alloy / steel spoked version, with a saving of nearly 20lbs.

Not so much saving on my front as it's 4LS - but still lighter. Straightaway there's 25 lbs of my 100lbs target reduction.

 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

DesmoBro said:
Who just hit me with a Salt Shaker?

Kick his ass CBass!!!

nice build so far man shed that weight!
LOL!! I knew that one was coming..... Dumb and Dumber is one of my favorite movies.

I actually named one of my other builds referencing a charater in another movie "The Mask"

CB550 "Ipkiss" - http://www.dotheton.com/forum/index.php?topic=25584.0
 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

beachcomber said:
FYI - the steel spoked alloy wheels are much lighter than the OEM swirly wheels.

I just sent a pair of redundant alloys off to a guy who is restoring a TR1 [ ? ]

I had to weigh them for the carriers to quote.

The rear wheel is TWICE the weight of the alloy / steel spoked version, with a saving of nearly 20lbs.

Not so much saving on my front as it's 4LS - but still lighter. Straightaway there's 25 lbs of my 100lbs target reduction.

I ended up buying the wrong XS650 hub and spoke. I wanted a 36 spoke and ended up buying a 48 spoke "special heritage edition" :(

I ended up selling it and purchased a 1978 xs650 36 spoke hub on eBay and ordered a DID 18x3 front aluminum hoop and custom spokes from Bucannans. Rear wheel will also be using a 15x3 DID rear hoop sourced from eBay :)

Now it'll be even lighter than steelie's ;) 8) 8)
 

beachcomber

TJ - Beachcomber
DTT SUPPORTER
Re: "CBass" -- Yamaha Virago XV750 Cafe Build

The XS500 and 650 rear hubs are virtually the same - I've used both.

I weighed the front [ WM3 2.15" x 18" ] wheel complete with the 2 brake plates and it's only a saving of 2 lbs over the swirly OEM alloy - still a saving though !

The rims I got are Borrani replicas WM3 and WM5.

 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build


- Valve Adjustment
- Checked Cam Chain Tensioner
- Cleaned for hours with toothbrush, sandpaper, and degreaser
- Prepped, primed, painted








 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build

- Aluminum parts chemically washed and polished
- Bought all new stainless steel bolts for engine covers and crankcase


There are soo many different length bolts and some shouldered bolts I needed to come up with some kind of inventory system and a diagram on how to re-install it. It worked for me ;)














 

T.Stanley

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Re: "CBass" -- Yamaha Virago XV750 Cafe Build



- Purchased front and rear Progressive Springs
- Installed Progressive front fork springs
- Lowered 2 inches with PVC rebound spacer
- New All Balls fork seals and dusters wipers
- Maxim 15w Fork Oil


Everything was a breeze............except for the damm c-clip on the top spacer!! I fought it for 30 mins taking them off and another 30 installing them. Wish I had a real press.




 
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