Juggernaut XS750 "Antichrome"

Juggernaut

Been Around the Block
This is the first motorcycle I can call mine. I picked the bike at the beginning of June for $300. It had not run in 6 years but included a few extra parts. The owner and I shoved the heavy beast on the trailer and I drove home happy and scared. The PO told me he thought the carbs needed to be rebuilt and that was about all. So began the journey.

Since then it has been a love and hate relationship. The beast never liked me. I rebuilt the carbs and gave it a new battery. It fired up but didn't run well. After lots of reading I started rebuilding/replacing everything that looked bad, leaked, or looked at me wrong.

Total that has been replaced:

- Battery 2x
- Plugs (4x)
- Wires
- Rebuilt the carbs
- Swapped points to electronic ignition
- Cleaned out gas tank
- Rebuilt petcocks
- New tires
- Powder coated wheels (Black)
- Replaced the air box with pods from Mike's XS
- New gas cap gasket from Mike's
- Changed all fluids except brakes
- Replaced the carb to engine boots
- removed carbs
- installed carbs
- removed carbs
- installed carbs (Repeat 10x)
- Replaced the clutch

Today (9/21/10) I got it running right after drilling a hole in the crank to relocate the pin for the ignition. Finally rode it home. The tires need to be balanced badly, and I need to get the speedo working.

I want it give it the cafe racer treatment. I want to paint the tank and seat dark blue metallic. The frame will be a dark red. Hide the electronics and battery in the seat to give it a really clean look.

This is how it looked when I was finally able to ride it home after it had been getting worked on at my cousins house. He has a massive polebarn with 6 dirt bikes.

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sxecafe

You think the Carpet Pissers did this?
Re: Juggernaut Cafe Racer

Word! It def takes alot of patience and more importantly money! Keep it coming man. You'll look back on all the work and hopefully at some point soon, you'll be able to smile at where you are.

Also, nice cousin you have there.
 

Juggernaut

Been Around the Block
Re: Juggernaut Cafe Racer

Starting small I decided to dive into the brakes. They were old, low on fluid, and nasty looking. The process too about 4 hours to get everything apart cleaned and labeled. All the calipers, mounting brackets, and master cylinder were stripped of their paint.

According to what I see I'm going to need the following:

- Possible new piston
- New bleeder
- Pads
- Caliper paint
- New SS hoses all around. (Mine were marked 3/76)
- Speed bleeders
- I need an education on the small pivot bushing with rubber boot. Shouldn't this piece be about to slide easily like a car caliper? I had to pound it out with hammer and socket. Worked great and no damage to anything.
- Get rotors turned. I can take off 1mm before the minimum.

1MostlyApart.jpg

Nastyness
2DirtandCrap.jpg

All the parts laid out
4CompletelyTakenApart.jpg


Then I removed the engine, suspension, swingarm and final drive. The engine was definately a two man job. I'm still dealing with a broken ankle as of September.

The engine finally removed (blue tape for all the stuff I'm chopping off)
Disassembled.jpg


Bars are about 1" from the tank and they feel perfect
DisassembledFront.jpg


I have also built an engine stand with wheels so I can move it where ever I want. It will also make cleaning it much easier.

Today I cut all the tabs off with my grinder. Only took 4 hours. Not bad, and all the sparks flying off made it seem like the 4th of July

The tank got the paint stripped and half sanded. After that fun I decided that it would be a good time to try and pop out the dent on top. First it got the fire and ice treatment...no good, tried it twice. Then I remembered reading on here or somewhere else to seal the tank and used compressed air to "blow it up". Bad idea. The top dent didn't move and I made a pretty large dent in the tunnel. This also pushed out the bottom side half out a little distance and my knee hits the petcock. The tank could be salvageable but it probably would not be perfect. So I'm in the market for a tank now. No good. The ones on e-bay are over priced and still look worse than mine.

In other news the calipers, torque plates, headlight shell, rear master cylinder, and kick stand have all be primed and some have been painted. Looking for a wiring harness. Most of the engine is cleaned but I'm a little nervous about painting since some of the paint flaked off on the cooling fins. I have also decided to let a professional sandblast the frame and swing arm since sanding by hand takes forever and is never perfect.

I have also started an excel list and I'm up needing about $800 in parts and services. This is seldom opened as severe depression sets in almost immediately. The Juggernaut trudges on.
 

VonYinzer

Over 10,000 Posts
Re: Juggernaut Cafe Racer

Good start Juggernaut! Not too many 3cyl floating around here! Keep us posted.
 

teazer

Over 10,000 Posts
DTT BOTM WINNER
Re: Juggernaut Cafe Racer

Do NOT do a spreadsheet and do Not ever add up the costs after you finished - unless you have shares in a make of anti depressant drugs.

I like to think of cheap bikes as a sort6 of installment plan. Of course each installment is basically whatever is in your account at the time.. :)
 

Juggernaut

Been Around the Block
Re: Juggernaut Cafe Racer

teazer said:
Do NOT do a spreadsheet and do Not ever add up the costs after you finished - unless you have shares in a make of anti depressant drugs.

I like to think of cheap bikes as a sort of installment plan. Of course each installment is basically whatever is in your account at the time.. :)

Agreed. I'm doing it so I can see the cost and also where I can buy it. If I find something at a better price I'll jump on it. My memory is for shit most of the time and then by the 3rd order from the same place I finally have all that I needed when I could have done it in one transaction. This is going to be a teardown and transform. The engine will come out again next year and I'll swap an 850 and over bore to 900. Who knows...I may be happy with just a 750 and mild build. ::)
 

Rocan

"Long after I rest, my steel will live on"
Re: Juggernaut Cafe Racer

you dont happen to post over at global-flat?

bmx flatland forum... you have the same username as someone there.
 

hillsy

Over 1,000 Posts
Re: Juggernaut Cafe Racer

Getting pretty rare over here in Oz those Yammie triples.

I've never worked on one, but I have heard the Triumph Trident carbs (IE mid 90's Hinkley ones) bolt straight up and are a nice power upgrade ;)
 

Juggernaut

Been Around the Block
Re: Juggernaut Cafe Racer

I think I read about those carbs. One of the guys from yamaha-triples said a turbo kit came out for it way back when. The engine is going to be left as is for now I want it looking pretty now and I'll do go fast mods later. I only rode it 40 miles before she got stripped down and only 20 miles when I set up the carbs properly.
 

Juggernaut

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

In the search for decent rear suspension. Everywhere I look there are high end shocks and low end shocks (price). Is there something in the middle that people recommend? Where can I learn about the specifics of them? I know the different types but not their benefits and specific use.
 

Juggernaut

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

So I've been thinking about the frame quite a bit as this is going to be the first part that will be redone. All the unnecessary tabs on the frame have been cut off. I think I shaved off around 7 lbs. The highway bars were each 6" long and solid steel welded to the frame.

After all the cutting/grinding I now have a few deep (1/16th") gouges from bad angles and being a first time with a grinder. I'm looking for suggestions on what to use as a filler. It seems there are several options. I have read that since the frame will be flexing a little that putty may be an option. I have also considered asking a welding buddy to just weld the gouges and then grind smooth. Am I correct that welding needs to be done within a certain temperature range? It's freezing here and the welder would probably be used in an unheated pole barn. None of the gouges are deep enough to be life threatening. Then the frame will be will be sandblasted. Obviously, if I went with a filler it would be applied after blasting.
 

.jordan

Active Member
Re: Juggernaut XS750 Cafe Racer

Juggernaut said:
So I've been thinking about the frame quite a bit as this is going to be the first part that will be redone. All the unnecessary tabs on the frame have been cut off. I think I shaved off around 7 lbs. The highway bars were each 6" long and solid steel welded to the frame.

After all the cutting/grinding I now have a few deep (1/16th") gouges from bad angles and being a first time with a grinder. I'm looking for suggestions on what to use as a filler. It seems there are several options. I have read that since the frame will be flexing a little that putty may be an option. I have also considered asking a welding buddy to just weld the gouges and then grind smooth. Am I correct that welding needs to be done within a certain temperature range? It's freezing here and the welder would probably be used in an unheated pole barn. None of the gouges are deep enough to be life threatening. Then the frame will be will be sandblasted. Obviously, if I went with a filler it would be applied after blasting.
If you want it done the right way, weld them and grind them back with a flap wheel to keep from going too deep again and this will minimize your work needed to get to paint ready. Obviously if they are pretty superficial you can just use putty. If they're smaller than a bead of weld, then I'd just putty them with a good automotive putty that is meant for metal.
 

rocketman

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

I am in the same boat with my(77 xs750 2d) frame. I took it to a welder to get a hoop welded on the rear but its off a little,went to deep with the grinder etc. I am going to fill bad spots with metal(braze) and then use body filler to give it a clean look. Keep up the good work!
 

Juggernaut

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

Thanks rocketman and jordan. It's going to a long build as funds allow. So many parts to get and I hate waiting for the garage to heat up. Rocketman, do you have a build thread on here I can follow?
 

rocketman

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

I am pretty much in the same boat. I have my bike all packed up in the garage. I had another child, moved and remolded a house so things are on hold until I get the garage unpacked and some kind of work area set up. My thread is here. I have lots of stuff planned so stay tuned!
 

CresentSon

Over 1,000 Posts
Re: Juggernaut XS750 Cafe Racer

Surface gouges in the frame shouldn't be a big deal, especially if they are in between two motor mounts, as the motor will take some of the stress. That being said, I err on the side of caution. If they are big enough to be note worthy, then they are probably big enough to weld if you have easy access.
 

Juggernaut

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

I haven't been doing a whole lot to the bike with the cold and snow being constant for the past two months. After a lot of sanding and cleaning of the engine, covers, triple tree, caliper mounting bracket, rear master cylinder, front brake line splitter, headlight shell, and kickstand. They all got painted black.

Timing Cover
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Triple tree top
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Engine and my homemade engine stand with wheels
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Under side of the engine
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Clutch and alternator side of the engine
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1 Box o stuff
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I'm getting ready to out the forks back together and wanted an opinion. The seat/tank are going to be dark blue and the frame is going to be dark red. Do I paint the forks the red or dark blue OR black? (the same as my wheels and engine)
 

jackstraw650

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

Hi Juggernaut! You just helped me out by answering a question about the XS750 gas tank cap on another build thread, so I thought I would come check your build out. I like where you are going........I've always thought the XS750 was one of the classiest bikes designed by the Japanese in the '70s-'80s....it should make a great looking custom build. By the way, I vote for black in the fork lowers sweepstakes!!
 

Juggernaut

Been Around the Block
Re: Juggernaut XS750 Cafe Racer

Thanks jack. Now I'm down to the big ticket items before I can start putting it back together. Good luck with your build.
 

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