HollywoodMX's xv920/TR1 Cafe super-dupe!

[HollywoodMX]

Here is my XV920RH / TR1 build, nothing makes it super dupe by the way..

I fell in love with the way the early 80's virago the engine sat in the frame but after building an XS750 I new a shaft bike wasn't for me as I didn't want to be limited by rear wheel swaps, the extra weight and drive train loss.So it was TR1 or bust! Plus I also fell in love with the frame chopped version of these bike which is popular on the other side of the ocean.

I bought this bike a year and half ago. It had a few problems; running on one cylinder, worn out intake boots causing visible explosions under the gas tank, leaky gas tank!! DANGER! lol. Thing overall ran like ass, started like ass. Front brakes were facked. WE'LL FIX THAT NONSENSE!

Despite the mechanical issues it was in pretty good shape, harness was in excellent shape, not dings, dents, or scratches, some slight rust, nothing major. I didn't do much with it except collect dust while I worked on my 77 KZ. After working on my KZ for a little over a year. I got to point of frustration pursuing perfection with. Plus I decided I'd rather go with custom gulwing triple tree's vs modifying the R1 ones so I benched the KZ until I get the trips.

So I switched gears to a my tr1 for a refreshing break of making more of a rustic cafe where it was ok to be a little ruff around the edges. Something I would crinch by hacking and welding ont he frame. Something that may look un-polished. I also wasnted to simplify my KZ harness so I though I'd rather learn on the TR1.

So what have I done so far?

Infamous Benelli tank (people may criticize that's its over done, I bought it 2 years ago and it sat on the shelf. I don't care thought so far its still the best looking tank for these bikes and a super easy fit.)
Build a new subframe (w/battery box)
Cleaned it up a little.
2 into 1 manifold and carb swap carb (Harley CV) what a pita
gsxr throttle
zx7 master cylinder
braided lines
Taylor plug wires
irridum plugs
Ricks starter
starter clip removed
I reconditioned the front calipers.
HID retrofit
motodynamic sequential LED tail
variuos cafe parts
simplified harness (pita part deux)
clip ons (still deciding on clip ons vs handle bars as I have a set of clubmans too)
velocity stack (velocity sock on the way)

What's in the boxes?

Dyna perforamnce mini coils
New mirrors
New mufflers
Progressive springs front and back
New paint! Gulf orange and gulf blue (I wanted to try single stage urethane w/hardener, vs dual to see the difference).

What is up in the air?

WHEELS! I have a set of 77 kz spoked wheels which I am sure I can get to fit with some custom spacers. But I dont really want to run tubes because I want to drop weight. I can go modern forks and swing arm (sooo tempted..) but I'm thinking I want to stay vintage on this bike, plus I already have progressive springs. So I'm hoping to find a tubeless option for xs650 wheels, if I can do that I will stay vintage (any help on that would be appreciated). If I cant I "might" go modern.

Engine mods, I want more powa! Need some help on this one too. The virago site participation on this subject is a bit of fail.

So where am I at in the build?

Just at the tail end of the wiring harness. I'm making a custom mandrel 1.75" exhaust (I'm hoping I can make it dual, equal length). We''ll squeeze in some frame chopping too. Hoping to get through most of this this weekend.

 

[HollywoodMX]

Issues adding more pics, trying this again.

 

[HollywoodMX]

At four pics a shot this is going to take a while..lol. 8)

 

[HollywoodMX]

Weeeeeeeeeeee!

 

[HollywoodMX]

still coming..

 

[HollywoodMX]

more..

 

[HollywoodMX]

Aaaaaand then. No and then!

 

[HollywoodMX]

Ok now we are caught up. Time to get to work on the bike yo!

http://www.youtube.com/watch?v=-fzjk9qwR0I&feature=c4-overview&list=UURFvcHavVgQRxT35yzeZxRA

 

[Zookrocker]

wow...this is looking amazing....following this one for sure!

 

[Rich Ard]

In. Overdone or not, the Benelli tank looks good on the v-twin. Nice work so far, though I'd suggest bracing your subframe a bit at the back.

 

[HollywoodMX]

In. Overdone or not, the Benelli tank looks good on the v-twin. Nice work so far, though I'd suggest bracing your subframe a bit at the back.

Ya I planned on bracing it, was waiting on welding gas which I have now.

I kinda when a few directions today...

First thing first to make the rear the exhaust time to cut the frame! I will clean up and box the lower cut tomorrow. I did figure out a way to make the rear equal length. This is something a lot of people short cut in the xv920/750 builds. No body like screwing around with making custom exhaust cause of the room around the rear pipe. Cutting the frame and dropping the center stand creates all kind of room.

 

[HollywoodMX]

and then!

 

[HollywoodMX]

Then I realized how hideous the enclosed chain is. I decided it had to go before any custom exhaust glory!

I also then realized how much I hate this enclosed chain system. What a mess taking that bitch off! So after taking it off I figure I would test the KZ wheels for shitz and giggles. They actually would work rear needs a custom spacer and a new rear brake, front needs a custom axle, a washer, kz spacer and the kz speedo drive.

It did sell me on the wire wheels but I'd rather go tubeless and the the xs650 swap.

 

[HollywoodMX]

wire wheels!!

 

[rundown]

I have to agree with Rich, that Bennelli tank is used a lot for a reason.

 

[hooligan998]

I'm not real familiar with XV mods, so I have to ask: Is that frame mod structurally sound? Will you leave it like that or tie it back together with some custom bracing?

 

[beachcomber]

I'm not real familiar with XV mods, so I have to ask: Is that frame mod structurally sound? Will you leave it like that or tie it back together with some custom bracing?

There's a whole 'nother thread somewhere about this !!

There's many arguments against from an engineering design viewpoint - and then there's Sepp Koch who successfully races with such a mod !

I'm in the naysayer camp - but that's just one opinion.

 

[HollywoodMX]

I'm not real familiar with XV mods, so I have to ask: Is that frame mod structurally sound? Will you leave it like that or tie it back together with some custom bracing?

It's quite popular mod on the other side of the ocean where the TR1 is more prevalent. If you search TR1 cafe racer most of the TR1's you will see have the frame cut, even more drastically. The ones you don't see that way are the virago (shaft) versions of the cafe builds. People have been running those cut frame for donkeys years.

I do have a pretty trick idea to re-enforce it though. It will be partly functional but its going to be more for show than go. I want to build the exhaust first.

 

[HollywoodMX]

Yesterday I reconfigured the welder for gas, did some more grinding of the frame and some re-welding of the frame. I will take pics of that today. I salvaged the stock exhaust flanges and started on the front pipe.

 

[HollywoodMX]

Exhaust fitment decision thread;

http://www.dotheton.com/forum/index.php?topic=54795.0