Topic: My cafe project progress

[swellguy]

I gotta ask, why you left the front master cylinder, out in the open, rather than under the headlight or tucked under the tank?

I'm using the BCR headlight mount which tucks the bucket closer in to the forks by an inch or two. My Yamaha gauges have the 90 degree angle adaptors so the stock bucket won't fit so I'm using a smaller aftermarket one. There is simply no room to fit it there.
There is also no room under the tank. I tried several locations that might have worked but was left with having to deal with the fluid reservoir. And I've got a rat's nest of cables running along the backbone that the gas tank doesn't do a good job hiding.
I kind of like where it is now. I'll probably paint the cylinder black to minimize the appearance and rework the cable connection so it's closer to the frame. But where it is now I can just run a short hose to the caliper and wires to the brake switch with a double banjo bolt.

[Really?]

Where are you at with this build?  SHORTROUND needs some competition in BOTM!

[754]

I see. I think you had mentioned you were not sure where you would put the wires. I ran a Bates style light on my 750 with a stock tank. I bundled up and taped the wires, and got them under the tank mount. If some were cut out, would be easier.

 Front brake switch, I could never  be bothered to run one..

[joe29]

WOW!  The pinstriping makes a huge difference!  Nice job!

BTW, what are those two extra bolts for on the cycle-x tripple clamp?

[HedNut]

Love the work on that seat and tank!   The seat pad is magical! And JESUS I LOVE THAT TAILIGHT!!

 

Cheers!
Is it ready for BOTM!?

[swellguy]

BTW, what are those two extra bolts for on the cycle-x tripple clamp?

The instrument mount bracket is custom affair and bolts on from underneath.

[swellguy]

Where are you at with this build?  SHORTROUND needs some competition in BOTM!

Hooking up internal throttle tonight. Mostly wiring and plumbing form then on. Stock loom is in good shape, just getting aftermarket switches and led signals adapted into it. Need to run fuel and carb hoses. Make new front brake hose. Chop/shape stock fender. Time the new ignition. Should be ready to go.

I have a box swingarm being built by Rob (voxonda) but I'm not sure when it gets here. With the newer rearsets I can run the bike without it for now.

[q2418130103p]

Never liked bar end mirrors that much. Always wound up getting a view of my elbows, so I adapted some hotrod peekaboo mirrors:



Yes, doing lots of little things while trying to avoid the headlight bucket wiring matter. But it's back from paint so I'm headed there now.

Thanks for all the positive feedback, it keeps me focused on getting it done . . . my way.

What switches/control are those?

[swellguy]

Generic ATV switches, from eBay, but places like Dime City Cycles and others also sell them.

[swellguy]

Fitted the internal throttle unit (sorry for the shakey photos):



Smooth travel throughout the entire carb slide range, snap return with single cable:



Going with the metalflake hammer grips for the moment (had to buy 2 sets of 1" grips get ones that were 4.75" long):

[Zaipai]

Good call on the throttle. Love the cable in the handle bars.. The grips are nice too.. Big pain?

.: Scott :.

[swellguy]

Good call on the throttle. Love the cable in the handle bars.. The grips are nice too.. Big pain?

.: Scott :.

The only real issue . . . once I got 7/8" tubing to fit the throttle . . . was simply doing it. Lots of fiddling with having an exact amount cable exposed from the end of the sheath, connecting and disconnecting the the cable from the carb a few times, nothing major just finicky.
If there's a weak point with this unit, there is no ferule molded onto the end of the cable inside the mechanism. It's a plug that clamps onto the end of the cable with a grub screw.
The one problem I did have was that the roller bearings (round silver pieces in the pictures) which actually slide up and down in the throttle sleeve groove were machined so the outside edges went past the circumference of the sleeve so they wound up binding to the inside of the grip . . . throttle would stay open until rolled back to idle. Took them out, filed some of the surface down to sit below the throttle sleeve edge and now it's just fine.
Grips were a bit of an issue. Standard 7/8" grips would fit both sides but I couldn't find any that had an internal depth longer than 4.5", the exposed throttle sleeve was 4.75" so I would up having to use the right hand grips from two Harley sets. Just beefed up the diameter of the left bar with black tape to get the 1" thickness and match the color of the sleeve since the grips are semi transparent.
The $7 Vespa repop grips were just crap.

[HedNut]

Internal throttle unit!  NEAT!  this is new to me...and it excites my cocals....

Cheers!
Great job!

[q2418130103p]

Internal throttle unit!  NEAT!  this is new to me...and it excites my cocals....

Cheers!
Great job!

This is the second post in a row that I have read from you that reference 'excitement'.
I am a little concerned for you ;-)

[HedNut]

  ...what can I say?.... they get the best of me.

[Zaipai]

Good call on the throttle. Love the cable in the handle bars.. The grips are nice too.. Big pain?

.: Scott :.

The only real issue . . . once I got 7/8" tubing to fit the throttle . . . was simply doing it. Lots of fiddling with having an exact amount cable exposed from the end of the sheath, connecting and disconnecting the the cable from the carb a few times, nothing major just finicky.
If there's a weak point with this unit, there is no ferule molded onto the end of the cable inside the mechanism. It's a plug that clamps onto the end of the cable with a grub screw.
The one problem I did have was that the roller bearings (round silver pieces in the pictures) which actually slide up and down in the throttle sleeve groove were machined so the outside edges went past the circumference of the sleeve so they wound up binding to the inside of the grip . . . throttle would stay open until rolled back to idle. Took them out, filed some of the surface down to sit below the throttle sleeve edge and now it's just fine.
Grips were a bit of an issue. Standard 7/8" grips would fit both sides but I couldn't find any that had an internal depth longer than 4.5", the exposed throttle sleeve was 4.75" so I would up having to use the right hand grips from two Harley sets. Just beefed up the diameter of the left bar with black tape to get the 1" thickness and match the color of the sleeve since the grips are semi transparent.
The $7 Vespa repop grips were just crap.

That does not sound too bad. I may have to work on that for next spring. Finding grips I like maybe the only issue. Thanks for the reply.

.: Scott :.

[Haywood]

Great build thread. I am using your bike as inspiration for my 74 CB750 build, I just hope I can swing your tank and seat combo, I love them! Any info on your velocity stacks? Would like to pick up a set of those.
Thanks!

[swellguy]

Man I get nervous whenever what I do becomes inspiration for others . . .
But, to answer your question, I have the 29mm Keihin cv carbs which come with stacks that are made for these carbs:



They are ported to fit the openings and are part of the $799 or so kit:



Again, I am still putting my running bike back together. Since getting these carbs I've read enough from other users to suggest they are anything from great to a total pain in the ass to tune. I hope within a month to have fluids going through the bike to make a better report.

Depending on how inspired you are you might want to PM me about certain parts, suppliers etc. I've used that you might eventually choose to avoid

[Roach]

wow those are some sexy carbs love the build.

where abouts are you located on the west coast?

[Syscrush]

Nice work, loving this thread!

[swellguy]

wow those are some sexy carbs love the build.

where abouts are you located on the west coast?

Thanks. Victoria and Vancouver. Bike is being built on the Island now.

[greenjeans]

Great build.   With that internal throttle, can you still run the wiring for the controls/switched in the bars ?

[Really?]

With regards to those switches, can you put together a list of what color wire went to what here in your build thread?

Please?

You started the inspiration thing, lol.  I am inspired. 

[Joksa]

Really nice bike and I really like the quality of the build. Only thing that doesn't make sense to me, is using these big and modernish universal switches (especially when putting effort to relocate brake master and using internal throttle). I would consider using black box or similar relay box and minimalistic approach for the switches.

[swellguy]

Great build. With that internal throttle, can you still run the wiring for the controls/switched in the bars ?

Thank you. I could run the wires inside on the left bar but the internal throttle unit extends too far into the right bar, well past the point where you could stick the wires through, or would make sense to do so.

With regards to those switches, can you put together a list of what color wire went to what here in your build thread?
Please?
You started the inspiration thing, lol.  I am inspired. 

I'll do what I can but I think it's fairly straightforward. Each wire is labeled as being for something and I'm just matching what the box says the wire is for to where the wiring diagram says it should go. Of course, I'm sure there are some surprises ahead.

Really nice bike and I really like the quality of the build. Only thing that doesn't make sense to me, is using these big and modernish universal switches (especially when putting effort to relocate brake master and using internal throttle). I would consider using black box or similar relay box and minimalistic approach for the switches.

Thank you. I know what you mean about the switches. They actually aren't all that big, they are smaller than stock switches. I am going to be using a few relays anyways. I did notice some recent changes to Dime City Cycles website that now offers smaller, universal, retro looking switches. Is this sort of what you had in mind?:





They're simple enough but at less than $20 I can't imagine the build quality is all that great and I don't think they do all the functions I need. I did look at these micro switch setups:



But found that the switches sat too far down into the bars which are made from fairly thickwall aluminum tubing. At this point though, if you've got some other units in mind I'd be curious to know about them. PM me if you'd like.