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Message started by scubachef on 12/10/11 at 20:03:37

Title: Cafe Conversion "the late night special
Post by scubachef on 12/10/11 at 20:03:37

Hey all, I wanted to introduce my project. It is a cafe build on a serious budget and hopefully will give someone else some ideas or inspiration as I have gotten from many other projects.
Please disregard the piles of junk in the background. Just moved and lots of stuff is just waiting for a home.
here it is at the beginning:
http://i1080.photobucket.com/albums/j339/chefsamurai/2011-09-20_18-08-53_982.jpg

progress:
http://i1080.photobucket.com/albums/j339/chefsamurai/2011-10-08_18-40-33_412.jpg

and its current state:
http://i1080.photobucket.com/albums/j339/chefsamurai/2011-11-17_17-20-21_961.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/cellphonepics11-23-11546.jpg

The seat foam and upholstery is not pictured here. No I don't ride with just the sheetmetal seat..ouch.
After searching for a project bike I stumbled across the Ryca conversion and then stumbled here. I bought a 97 Savage and set out to do a cafe conversion, admittedly riffing ideas from the Ryca guys as a foundation, but also completing the bike coming up with some ideas and fabrication of my own. I am calling this the late night special because I completed it largely between the hours of 10pm and 2am. I just had a kid and my wife made me the deal I could pick up another project if it didn't cut into family time. I budgeted out the build, including the parts and materials left to purchase, at $800.00 not including the cost of the bike which was $1,500.00. Again, I made the deal that I would not touch our bank account to fund the bike so I sold some car parts to make the motorcycle fund. So far I am at $764.00. Sorry I didn't take more photos i was just kind of trying to get it done so I could get back to riding. It isn't nearly finished yet. I am making another seat (i got the idea for this one from the cb450 Rpnsht posted a link to) but it rushed it and I am not happy with the outcome. I am going a different direction with the new version. The paint will be something in the realm of the paint scheme of one of my favorite cafes pictured here- http://www.bikeexif.com/yamaha-xs750

I wanted to throw this out as an idea for those who might want to tackle a cafe build but don't have the cash for the Ryca kit. I have no ill words for Ryca or their kit. I think they did a pretty great job and had some great vision to see what the bike could be. I just don't have the cash for it. I used the gauges, clip ons, and speedo cable from the kit purchased here from BuckRyca (thanks!!) and bought my rearsets from fastfromthepast.com. I fabbed the rest of the parts needed, and am still making stuff and working out ideas but for now it is very ride-able and I use it as my daily driver. I do 62 miles round trip on the freeway here in SoCal and it performs great. It looks s a little "rat rod" now but by the end I should have a polished bike I will be proud to show off for approx $2,300.00 total. I used some stuff I already had from previous projects (that seat used to be part of a repro 69 camaro quarter panel ;)) so to replicate it would cost slightly more than I have in it right now but I thought it might spark someone else to dive into a cafe build even if they are a little short on cash. Thanks for all the tips and tricks I have picked up here. I will post progress on the bike as I finish it up.

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/10/11 at 22:08:54

That looks like it's going to be a lot of fun!
I'm right behind you, man... just posted my build thread a few minutes ago, and found yours here tonight too.
Wide awake and posting stuff while our wives and babies sleep...

Cheers!
And good night!

Title: Re: Cafe Conversion "the late night special
Post by justin_o_guy2 on 12/10/11 at 22:50:22

Looks good, I sure like the peg location. Personally, I really like the No front fender look,, I just cant see me taking the crud coming off the tire.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/11/11 at 07:58:20

Agreed the no fender look is more form than function for sure. I still might end up running a front fender if I find myself eating dirt and grime too often. I welded in some sheetmetal to enclose the back of the frame to help cut down dirt back there but just like the look too much to run the front fender.

For the rearset location I used a plum bob to mark the centerline of the rider (or where I ride at least) and measured my leg from knee to foot to find a spot where I felt would be most comfortable and give my desired stance.

Thanks for the kind words!

Title: Re: Cafe Conversion "the late night special
Post by RpNSht on 12/11/11 at 23:21:12

congrats on the build! we almost have matching seat pans:

http://i1226.photobucket.com/albums/ee419/rpnsht/IMG_2878.jpg

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/12/11 at 12:34:21

2636203734363D3033550 wrote:

If you didn't use the RYCA footpeg mount bracket, can you show us how you got them mounted? They look perfect!

Title: Re: Cafe Conversion "the late night special
Post by EJID on 12/12/11 at 12:52:53

Interesting setup you have there...I like it for a cafe style bike. What catches my eye of curiosity is the rear reservoir style shocks you've got there... :o ... What are they? How do they compare to stock in ride quality and eye to eye distance?

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/12/11 at 13:39:55

Teabowl13, the mount for the rearsets is essential the same design that Ryca used. I thought of a few ideas and thought of making mounts welded to the frame, etc. I could not find a better solution so I took that idea and put my own spin on it. I used a piece of 1.25"square tubing that runs underneath the bike from peg to peg and welded all brackets to it. I will try and snaps some pics when I get home.

The shocks are RFY shocks and can be found on ebay. I did some legwork and found most people panned them for being a chinese knockoff of something like an Ohlins (which they are) but one guy on dotheton.com got some and took them apart to see what the deal really was. If you look on the site his avatar is CrazyPJ.
Turns out the parts are good but the assembly is horrible. So with some fluid, charging with gas/air, and some adjustment to the preload they actually perform pretty well, and cheap at $70.00 for a pair of re-buildable shocks. eye to eye is 12.5 but they come in different sizes. bushings are too small, it required some finesse to retrofit with your original bushings. I am playing with pressures and preload but so far the ride has been good. I actually am going to stiffen them up for handling but as is they are a comfortable ride.

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/13/11 at 10:06:21

That was really smart to do your research on those shocks. I had looked at those too, but decided on the Vintage RedWings that I got because they will fit the look and theme of my bike better. I think they are super sexy, but then again, I paid $200 for them!

http://p1.bikepics.com/2011/12/10/bikepics-2314665-full.jpg

We had the same issue with the shock bushings.
Even though my shocks were NOS and came with two sets; 10mm, and 12mm, which are the most common sizes, they were still too small, so we had to ream the rubber bits out and squeeze in the bushings from the stock shocks. Not too hard to do, but not fun either....

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/13/11 at 10:09:48

I meant to say,
I'll bet it's loud as stink, but I like the look of your exhaust pipe. Did you make that yourself? What's the muffler part on there, or is there one?

(And I don't mean to be a jerk, but if you can get that thing out into the daylight, you'll probably get much better pictures. I'll bet you bike looks much better in real life than your pictures show...)

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/13/11 at 10:38:29

you're correct, cell phone pics in bad light don't really cut it. The bushing situation wasn't hard but as you alluded to, time consuming and a little frustrating. I had 12mm bushing that came with mine as well...bummer. I love your shocks, for your bike's style that is the perfect choice.

I did make the pipe and it does have a baffle. I cut the stock pipe off just before the reducer and with it on the bike took a tig welding rod and bent the shape I wanted. Took that to the muffler shop and had a pipe bent up. There is a glasspack baffle from MAC exhaust welded in, and some BBQ paint to give it color. I am happy with the sound, and the look was just what I wanted.

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/13/11 at 10:45:22

Yeah, that looks like a real purpose-built, no fooling around race exhaust. Nice job with budget parts!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/13/11 at 14:32:44

Here are some pics of the mount as promised.

http://i1080.photobucket.com/albums/j339/chefsamurai/2011-12-13_13-54-02_703.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/2011-12-13_13-53-42_298.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/2011-12-13_13-53-34_223.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/2011-12-13_13-53-16_621.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/2011-12-13_13-54-20_44.jpg

The mounting bracket for the rearsets is equally spaced from the brackets that bolt to the engine mounts. You can see a difference in spacing between the swingarm and the rearsets due to the shifter side of the swingarm bowing out. Instead worrying about the gap between the swingarm and the rearsets I made sure my feet would fall to the same place on both sides of the bike but for looks someone might bring in the bracket on the brake side to make sure the gaps match. I have measurements and a little diagram for those really interested I can pm it. The picture from the top shows the square tubing used to brace the brackets attaching the unit to the engine mounts. I stood on the pegs and bounced a few times and it was rock solid.

Title: Re: Cafe Conversion "the late night special
Post by RpNSht on 12/13/11 at 17:30:21

chain conversion?

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/13/11 at 21:00:30

Hell yeah, just trying to figure out the perfect combo. Lots of freeway crusing as well as running around town and in the hills, so I think there might be some trial and error to figure out the best compromise. I want my cake and to eat it too.

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/14/11 at 05:27:41

I'm doing a chain conversion myself, so I posted up a few questions in this thread, and got a lot of info. If you haven't read this stuff, go here:

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1321556481

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/29/11 at 11:11:37

the new tail section begins................

threw this together a few days ago to see how i liked the shape. Thoughts?

http://i1080.photobucket.com/albums/j339/chefsamurai/IMG_1081.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/IMG_1082-1.jpg

Title: Re: Cafe Conversion "the late night special
Post by RpNSht on 12/30/11 at 20:39:37

are you in los angeles?
the 49/18 combo would suffice
im tearing up hollywood right now with the 45/17
my bike is overkill for all this la traffic
but i just couldnt bring myself to ride around one of those hipster scooters :)

322234232022292427410 wrote:

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 12/31/11 at 08:40:53

I'm in South Orange County. Thanks for the insight. I ride the 5 and the 405 to and from work so I need to be able to cruise at freeway speeds but I also take the bike up Ortega Highway (familiar?) which is a great 2 lane twisty. With your combo what do your rpms look like at freeway speeds?

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 12/31/11 at 12:16:49

I like the tail section so far; hard to tell at this stage from the photos what it's going to look like on the bike itself. Take a shot of it in place so we can see... and tell us what your plan with it is...
It does seem rather square compared to the stock tank... I don't know if that's a good thing or not... Have to see it to decide...

Title: Re: Cafe Conversion "the late night special
Post by RpNSht on 01/03/12 at 19:38:33

3D2D3B2C2F2D262B284E0 wrote:

5k at 90mph

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 01/08/12 at 20:45:43

Right now I run 4500 at 70 :( Running the stock rear tire though.

got work done tonight....

cam chain tensioner modified
valves adjusted
everything buttoned back up and no leaks..... success!

Title: Re: Cafe Conversion "the late night special
Post by jay313 on 06/01/12 at 05:28:55

Been lurking around here a long time for my own semi-Ryca build. Had to get myself up to 10 posts so I could PM you for that drawing/measurements on your fabbed rearset mount! Lol. PM sent. Thanks for being so helpful with the thread and pics.

Title: Re: Cafe Conversion "the late night special
Post by skeebo on 06/01/12 at 05:40:29

Damm Scuba you don't mess around do ya.......very nice man.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 06/01/12 at 08:17:14

Thanks everyone. Jay I will send you the measurements when I get home. The bike is still a work in progress. In the works are a tank from a xs750 and a subframe style seat. Paint will be a dark grey metallic with white and dark red accents. Once those get checked off mag wheels will become priority. I will be sure to document the next changes.

Title: Re: Cafe Conversion "the late night special
Post by singlesgoinsteady on 06/01/12 at 08:46:34

Rad, nice job!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/01/12 at 16:48:16

This build isn't dead I promise, just slow. made a new tail that I like so far. It angles up a little, and I think will work well with the new tank a XS750E that I should pick up next week. It is just all tacked together in the pics, finishing should be in the next day or two. I have given up on my dream of yamaha xs wheels for now. I could find wheels to work but it would not allow me to run a tire as wide as I want so I got a set of 82 gs550 wheels (19x1.85/16x2.75) that I will begin fitting soon. If I read everything correctly the 550 rotor will not work???

I also found what I think it the ideal use for the stock speedo hole as seen at the bottom.

http://i1080.photobucket.com/albums/j339/chefsamurai/2012-07-02_08-01-38_479.jpg
http://i1080.photobucket.com/albums/j339/chefsamurai/2012-07-02_08-01-21_57.jpg
http://i1080.photobucket.com/albums/j339/chefsamurai/2012-07-25_14-22-07_971.jpg
12 miles doing 75mph and not a drop spilled :)

Title: Re: Cafe Conversion "the late night special
Post by braveteacher on 08/01/12 at 17:39:03

Cup holder...good stuff...

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 08/02/12 at 07:31:53

This build SHOULD be dead... at least for now; it's time to go out and ride that thing! (HA! look who's talking....)

Just kidding; I like your new seat loop, and I can't wait to see it with the tank on. Lots of folks talking about tank swaps these days, you'rs is a new one. I'll be very interested to see how it comes out!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/02/12 at 16:06:49

It gets ridden...part of the reason it is moving a a snail's pace. It is my daily transport so I have been trying to make everything bolt on for the most part so I can do some work, bolt the old tail, etc. back on and get to work. Tough to not take it, bike mpg=50's truck mpg=high teens
My pocketbook says I better ride.

Title: Re: Cafe Conversion "the late night special
Post by teabowl13 on 08/03/12 at 06:50:11

49594F585B59525F5C3A0 wrote:

It gets ridden... My pocketbook says I better ride.

GOOD TO HEAR IT!
Pocketbook, schmocketbook; it's just more FUN to ride!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/03/12 at 14:54:31

18292D2E233B207D7F4C0 wrote:

GOOD TO HEAR IT!
Pocketbook, schmocketbook; it's just more FUN to ride!

You speak the truth ;D

The Tail section lives! Messing around with a seat....we'll see :-?

http://i1080.photobucket.com/albums/j339/chefsamurai/2012-08-03_14-17-06_143.jpg

http://i1080.photobucket.com/albums/j339/chefsamurai/2012-08-03_14-15-45_684.jpg

Title: "the late night special" still lives
Post by scubachef on 02/27/14 at 12:09:02

I'm back on the bike and wanted to begin posting again in the hopes that I will have this finished shorty. The plans as of now are to go the monoshock route, new (to the bike) tank, cleaning, painting prepping, etc.
I finished converting to mag wheels and now am focusing on fabricating a new swingarm and converting to monoshock. With this will come a new subframe and rear cowl along with the xs 750 tank I mentioned earlier in the thread. The end result in my mind looks something along this line:

http://2.bp.blogspot.com/-tNSmEXknxpk/Tv2RSlboTQI/AAAAAAAAJF4/Mx2zOBHF5nU/s1600/yamaha-xj-550-cafe-racer-3.jpg

I replaced my battery with a mini unit from Western Powersports that was 85.00 including shipping from Amazon. I read good reviews so I got it and am very happy I did. Great little battery and less than a pound. I fabbed a box using the old battery box cut down and mounted in the stock location.

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zpsdd17ba3c.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zpsdd17ba3c.jpg.html)

http://i1080.photobucket.com/albums/j339/chefsamurai/IMG_2158_zps10ca4795.jpg (http://s1080.photobucket.com/user/chefsamurai/media/IMG_2158_zps10ca4795.jpg.html)

http://i1080.photobucket.com/albums/j339/chefsamurai/IMG_2279_zpsd01ed492.jpg (http://s1080.photobucket.com/user/chefsamurai/media/IMG_2279_zpsd01ed492.jpg.html)

Hopefully more updates coming soon.

Title: Re: Cafe Conversion "the late night special
Post by ToesNose on 02/28/14 at 07:36:52

Great to see you posting progress on the bike again, you do some cool stuff ;)

Title: Re: Cafe Conversion "the late night special
Post by Arnold on 02/28/14 at 08:29:09

Can you charge that battery with a regular charger or does it take a proprietary?

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 02/28/14 at 08:34:07

Thanks Toes! The best is hopefully yet to come!

The battery does not require a special charger. Thier claim is a charge to 90% I believe in around 6 minutes and a full charge in an hour. I haven't had to charge anything so I have no idea if that is the truth.

Title: Re: Cafe Conversion "the late night special
Post by bobdog on 03/26/14 at 17:05:56

Could you post the numbers off that battery, thinking of goin smaller also ? Thanks much !!

Title: Re: "the late night special" still lives
Post by v-pilot on 03/26/14 at 18:40:46

6777617675777C7172140 wrote:

I'm back on the bike and wanted to begin posting again in the hopes that I will have this finished shorty. The plans as of now are to go the monoshock route

Hopefully more updates coming soon.

If you won't be needing the shocks, I'll give ya what ya got into 'em plus shipping ::)

Title: Re: Cafe Conversion "the late night special
Post by shorty on 03/27/14 at 11:09:23

enjoying this thread...nice work

Title: Re: Cafe Conversion "the late night special
Post by strang on 03/28/14 at 03:46:25

What's the bike like to crank in the morning with that battery?
I really want to go this small but I've heard they're no good for a cold start.

Title: Re: Cafe Conversion "the late night special
Post by Dave on 03/28/14 at 03:57:26

212620333C35520 wrote:

What's the bike like to crank in the morning with that battery?
I really want to go this small but I've heard they're no good for a cold start.

As long as your bike starts up quickly the smaller Li-Ion battery is fine, as they can supply good amperage for running the starter. The downside of them is that the amp-hours are about half what a lead acid battery is.....so you can't crank quite as long. The Li-Ion manufacturers claim that the lead acid battery gradually loses voltage as it cranks - while the Li-Ion battery holds the voltage right to the very end and then falls flat in a hurry.....which can ruin the Li-Ion battery if you run it flat.

I have an Earth-X battery, the bike does not sit outside and I never ride when it is much below 60 - but it starts my bike right up and this will be my second year with it. Somebody else is going to have to give you a report on real life cold weather starting - but the numbers show the bike will start fine in the cold.....providing you don't have to crank for an extended period.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 04/30/14 at 23:02:07

Been working on the bike lately finally trying to finish up what I was envisioning. I got the monoshock mocked up and got the new subframe fabbed.

Lower shock mount tacked together. I took a measurement of the ottoman shock mount and used a bolt and a few nuts to adjust and hold the tabs where I needed them during welding so warping would not affect the spacing.
http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps43654b2c.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps43654b2c.jpg.html)

Final welded

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps1c411edd.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps1c411edd.jpg.html)

Top mount in and shock mocked up. Still need to put in some bracing just for the sake of overbuilding!

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps77004a98.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps77004a98.jpg.html)

I'm going to run this to assess the ride and see if this shock and it's spring rate are going to be the ticket. I am expecting some flex in the stock swingarm. I definately don't think the stock swingarm is designed for this kind of stress long term. I plan on fabbing a tubular swingarm if the shock works out since it will be based on the length of the shock I wanted to try it out before building the new one in case I need to make some changes in shock angle or position. I'm no an engineer so the leverage calculations revolve around me drinking a cold one whe staring at the bike. The reason I decided on this shock orientation is it doesn't interfere with my pod filter. I have about 2 inches of clearance with the design which is more than I needed to remove the carb or filter.

New subframe beginnings.

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps7330f51e.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps7330f51e.jpg.html)

It is remove able and mounts in the back via a threaded insert I made and welded into the frame tubes and mounts in the front to the tank mount.
A sheet metal tail section is comin hopefully in the next day or two. I'm stripping the tank and subframe as we speak and will be prepping for paint a soon as the fabrication is done. Stay tuned, I'm hoping his will come out like what is in my mind! Hopefully like no savage yet.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 04/30/14 at 23:27:00

Sorry for the late replies...

Bobdog here is a link
http://www.wcpmx.com/WPS_Featherweight_Lithium_Batteries_p/wps_lithium_batteries.htm

I looked up the Cca of the stocker and his has 10 more!

V-pilot, the shocks are from eBay. Free shipping from seller gets them cheaper to you than me shipping them so you would come out ahead cash wise. They do need some work out of the box but it isn't that hard. I can send instructions if needed.

Title: Re: Cafe Conversion "the late night special
Post by SavageCat on 05/01/14 at 06:28:23

Good work, love the monoshock look.

If you're interested in letting your old shocks go then PM me please.

Thanks!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 05/02/14 at 10:31:05

I try to find ways for quality results on a shoestring budget. Here are two modifications/fixed that cost me a grand total of $11 and should hold up for the long haul.

Headlight repair

As is shown in the pic below, my headlight bucket snapped at the base. I assumed that vibration might be the culprit. I scuffed everything, wiped it down with acetone and epoxied the broken pieces together. Once the repair had set for about 20 minutes I taped around the perimeter of the base and filled the back of the headlight base with the epoxy. My thought was that the stress is now absorbed by all surface in the base since the all are now essentially connected instead of the plastic base being able to flex and eventually crack as I suspected was the case originally.

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps33009e6a.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps33009e6a.jpg.html)
http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps412c3a4d.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps412c3a4d.jpg.html)

Smooth Top Triple Tree

To smooth the top triple without access to a mill and lathe I took 2ea 3/4in fender washers, plug welded the hole and turned down the OD by chucking them in the drill press until they were a snug fit in the top triple's riser holes about 1/16 in below the top of the tree. I drove them in with a large socket and used steel epoxy to fill the 1/16in gap and also epoxied the bottom of the washer around the perimeter to lock it in even more. After some scuffing, sanding and a coat of primer here it is.
http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zps58415b71.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zps58415b71.jpg.html)

I'm going to paint with brake caliper paint. It is chip and chemical resistant and I think it is the toughest finish short of powdercoat I've come across.

Both these were quick and easy, hopefully this helps someone else!

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 05/31/14 at 18:19:21

Made some progress on the bike. Here is how is sits at the moment.

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/2014-05/C6667A0F-CD42-4598-82F8-D7ECD2C48926_zpslcvd9iwc.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/2014-05/C6667A0F-CD42-4598-82F8-D7ECD2C48926_zpslcvd9iwc.jpg.html)

I'm going to modify the tail to give it more angle but here are some pics of where it is right now.

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/2014-05/4BADC4DD-38E6-45A3-A2E2-1F99D87DB2F3_zpsndqwrcvw.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/2014-05/4BADC4DD-38E6-45A3-A2E2-1F99D87DB2F3_zpsndqwrcvw.jpg.html)
http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/2014-05/EB2A3B0B-B728-4613-9A27-4A7017664925_zpsnhy9ixbc.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/2014-05/EB2A3B0B-B728-4613-9A27-4A7017664925_zpsnhy9ixbc.jpg.html)
http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/2014-05/623AF680-1D7D-4559-A2EB-E676A3E5606E_zps2o2yy4sv.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/2014-05/623AF680-1D7D-4559-A2EB-E676A3E5606E_zps2o2yy4sv.jpg.html)

I'm going to tackle the rearset bracket and bodywork soon. Right now I'm sorting through the monoshock set up. This shock is way too soft so I'm looking at options and once that is wrapped up I will be on the home stretch.

Title: Re: Cafe Conversion "the late night special
Post by copterdoc on 05/31/14 at 19:30:40

Where did you get the redwings? I love. them, I need a set!

Title: Re: Cafe Conversion "the late night special
Post by ToesNose on 06/01/14 at 13:14:52

Coning along really cool Scuba, looking forward to more progress reports!

Title: Re: Cafe Conversion "the late night special
Post by strang on 06/02/14 at 03:33:37

very creative scuba, love it.
mags look bollocks cool on a savage.
I say keep the half finished tank - à la Wrenchmonkees. 8-)
How'd you do your pipe bends? old school sand method?

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 06/02/14 at 07:56:54

I did use the sand method as well as a modified harbor frieght pipe bender. I can't afford a tubing bender so I got the pipe bender at HF for 70.00 and did some work to modify it. Didn't take too long and works alright. Not the best for thinner tubing but it does ok.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/13/15 at 19:28:59

Hello all, my project and I are back from a long hiatus and almost ready to hit the road....but it seems like I have a wiring issue that might put the brakes on that. I numbered all the wires during teardown, so I'm fairly confident all connections are made as they were when I disconnected everything, but it doesn't start. I did lengthen some wires and did so with soldered connections and heat shrink...I believe all work was done correctly with no mickey mouse shortcuts When I hit the starter it sounds and feels like the battery is dead (starter barely makes a sound) but the battery was fully charged and checked with a multi-meter. The battery immediately got hot and began to hiss. I'm concerned the battery just got ruined, but more concerned that there is something in the wiring that caused the issue. So for clairity:

-labeled wires at teardown, matched numbers to re-connect
-charged the battery, checked it with a multimeter and it read 12.7
-hooked up battery, clutch in, starter button hit and no start but clicking from decomp is heard
-battery heats up badly and immediately loses charge, makes hissing sound. battery recharged, 12.7, same issue again.

Wiring and electrical is my kryptonite, does this issue sound familiar to anyone and/or can anyone give me some guidance on how I can check the various parts of the electrical system to verify something isn't wrong in the wiring that would cause this to happen and fry the battery?

Thank you in advance for any help that can be offered...and its good to be back! :)

Title: Re: Cafe Conversion "the late night special
Post by LANCER on 08/14/15 at 08:09:29

Electrical is my weak point too, but with the immediate response you get with a hot battery it sounds like you have some wires reversed somewhere.
You labeled them, but could have made the error when labeling. ? ?

Title: Re: Cafe Conversion "the late night special
Post by Gary_in_NJ on 08/14/15 at 09:00:21

Sounds like its wired into a dead short, probably at the starter solenoid.

Could the battery be connected in the wrong polarity (i.e. backwards)?

Title: Re: Cafe Conversion "the late night special
Post by oldNslow on 08/14/15 at 09:08:06

It sounds like you've got a dead short from the battery to the chassis when you try to engage starter. If there are no melted wires anywhere and the fuses didn't blow I'd suggest starting the search at the starter and the starter relay and the associated wiring.

Pull the starter out, clamp it in a vice and run it with jumper cables. If the starter is ok , then make sure that the eyelet on the wire that runs from the starter relay to the starter is ONLY touching the threaded post on the starter - that it isn't somehow touching the starter housing itself.

I don't know how likely it is for the relay to short to ground through its housing when it closes but I think it's possible. If that happens the relay should get pretty hot as soon as you hit the start switch.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/14/15 at 22:39:36

Im positive the battery is hooked up correctly and there are no blown fuses or melted wires. I will test the starter and see where that leads. Thanks for the replies! Here are some updates pics too.

Paint finished- Ferrari Grigo Silverstone
http://i1080.photobucket.com/albums/j339/chefsamurai/122714097_zpsc12eac78.jpg (http://s1080.photobucket.com/user/chefsamurai/media/122714097_zpsc12eac78.jpg.html)

Needed to modify a set of 7/8 mirrors so I made some recessed and threaded adapters that mount inside the bars with set screws
http://i1080.photobucket.com/albums/j339/chefsamurai/122714107_zpsa1546cdf.jpg (http://s1080.photobucket.com/user/chefsamurai/media/122714107_zpsa1546cdf.jpg.html)
http://i1080.photobucket.com/albums/j339/chefsamurai/122714112_zpse79e11d1.jpg (http://s1080.photobucket.com/user/chefsamurai/media/122714112_zpse79e11d1.jpg.html)
http://i1080.photobucket.com/albums/j339/chefsamurai/122714116_zpsfdbbeb0f.jpg (http://s1080.photobucket.com/user/chefsamurai/media/122714116_zpsfdbbeb0f.jpg.html)

http://i1080.photobucket.com/albums/j339/chefsamurai/image_zpse81d316c.jpg (http://s1080.photobucket.com/user/chefsamurai/media/image_zpse81d316c.jpg.html)

Title: Re: Cafe Conversion "the late night special
Post by justin_o_guy2 on 08/14/15 at 22:54:21

what kinda multimeter you using?

Title: Re: Cafe Conversion "the late night special
Post by chzeckmate on 08/15/15 at 00:26:43

That's bitchin'...I mean it, you've really got something going there!

Title: Re: Cafe Conversion "the late night special
Post by strang on 08/15/15 at 03:17:58

enjoyed the update Scuba - bike looks crappity smacking outstanding.

Title: Re: Cafe Conversion "the late night special
Post by Boogie_with_Stu on 08/15/15 at 15:02:33

You've done some outstanding work there Scuba! That color of grey/silver is one of my favorites and looks perfect on that bike. Sheet metal fabrication looks great as well!

I've never been a fan of a "blacked out" engine. It just doesnt appeal to my eye the way the polished aluminium does, but other than that....bike looks sierra hotel dude.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/15/15 at 20:47:09

Thanks everyone, can't wait to be riding it again after a long wait. Justin O Guy, the multimeter is an Equus brand.

Title: Re: Cafe Conversion "the late night special
Post by nof1 on 08/17/15 at 15:04:19

nice read. Cool to see the evolution. I like the stance.

Title: Re: Cafe Conversion *Now with electrical issues :(
Post by scubachef on 08/18/15 at 09:32:56

Few more electrical questions before I spend this afternoon hunting the issue I'm having. Bear with what I know are basic questions...and thanks in advance. I'm checking to make sure everything is wired correctly but am a little confused by the Clymer's wiring diagram. Can someone verify that the wiring of my starter solenoid is correct? specifically the yellow/black and the black/white wires on the two smaller terminals are. Here is how I have the solenoid wired

http://i1080.photobucket.com/albums/j339/chefsamurai/Starter%20Solenoid_zpsz0bpbmd5.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Starter%20Solenoid_zpsz0bpbmd5.jpg.html)

I want to check the solenoid itself. I see the Ohm range of 2-6 but am not positive what position to set the multimeter. Here is a pic of the multimeter I'm using, Which position on the Ohm side should I set it to?

http://i1080.photobucket.com/albums/j339/chefsamurai/Mobile%20Uploads/image_zpsf7p1h7qb.jpg (http://s1080.photobucket.com/user/chefsamurai/media/Mobile%20Uploads/image_zpsf7p1h7qb.jpg.html)

This afternoon I am going to test the starter, the solenoid, and if needed run the wiring from the right handlebar switch back to see if anything is pinched/damaged, etc. Thanks again for the help.

Title: Re: Cafe Conversion "the late night special
Post by Dave on 08/18/15 at 09:59:51

The Yellow wire goes to the Decompression Controller, the black wire goes to a ground.

Title: Re: Cafe Conversion "the late night special
Post by chzeckmate on 08/18/15 at 11:02:22

If you want to do a real quick check on the solenoid you could just connect your yellow wire to the positive on your battery and the black wire to the negative. You should hear the click of the magnet moving up. That's a pretty sure bet it's working. If you wanna be certain then you also connect your multimeter to the other two terminals and check for continuity. When you touch the yellow to positive and black to ground you'll hear the click...keep holding them there and then you'll either see a reading on your multimeter (some even beep) which means it's good or it'll show no continuity which means it's bad. The continuity setting is the one that looks like a soundwave.

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/23/15 at 22:54:23

I tested the starter solenoid for continuity and think it is bad, but I have a few questions. The battery was not in the bike for the test. I tested the two smaller terminals, multimeter beeped and the reading was 5. Testing the two larger terminals, no beep and a reading of 725.

I'm a little confused by the Clymer's. It says on page 238 in the area about testing the solenoid to disconnect the battery wire(+) and the ground wire(-) from the large terminals. I have one large terminal with a wire from the battery, and the other with a wire to the starter...no ground. Is something wrong with the bike, the manual, or me?

Title: Re: Cafe Conversion "the late night special
Post by chzeckmate on 08/24/15 at 01:23:19

I saw that too...maybe an error in translation?

The solenoid is just a switch. If you connect the batt + to the yellow and the batt - to the black wire you should hear a click if it's working. While you have the black and yellow wires connected to the batt you can put your multimeter on the two larger terminals and check for continuity (or resistance if you prefer). If you get a beep then you know with absolute certainty that it's working.

Basically what's happening is when the battery is connected to the yellow and black it charges the electromagnet and the magnet moves up and bridges the two larger terminals. That's when the switch is closed. Disconnect the batt and the magnet stops bridging...switch open.

The pertinent bit of the Clymer instructions are in step 9.

http://i1297.photobucket.com/albums/ag28/justin_fisher2/solenoid_zpsfwxw05k1.png (http://s1297.photobucket.com/user/justin_fisher2/media/solenoid_zpsfwxw05k1.png.html)

Title: Electrical issues
Post by scubachef on 08/24/15 at 19:38:53

The solenoid checks out good tested per the Clymers manual. I'm still confused why I got such a weird reading testing it when it was on the bike. I tested it three times and got no beep and 725 on the screen. :-/

Does anyone know how I could test the decomp controller? Anyone have a picture of how the handlebar switch should look internally? I think I put it back together correctly, but I am trying to go part by part to find my issue. Thanks.

Title: Re: Cafe Conversion "the late night special
Post by justin_o_guy2 on 08/24/15 at 21:02:12

You can't check ohms on a circuit with power to it.

Title: Re: Cafe Conversion "the late night special
Post by trevorw on 08/25/15 at 16:21:52

Did you figure out why your bike isn't starting? I kinda skimmed through your thread and looked at the pics haha! I had a problem with my bike, it wouldnt start, i got a new solenoid, not the problem, new battery, not the problem, hooked up the starter to straight power and it wouldnt go, so I figured it was done, I took it apart and one of the magnets in there had come apart. I cleaned it up and took all the broken magnet out, put it back together and it started just fine, also I was wondering if you could pm me the dimensions of that sweet rearset bracket you made, I am looking to do something similar to my savage, I cant send pms yet:(

Title: Re: Cafe Conversion "the late night special
Post by justin_o_guy2 on 08/25/15 at 21:13:04

Connect the voltmeter to the starter hot wire and chassis ground. Prove it is not getting power.
If it's getting power then go back, read my posts,

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 08/25/15 at 21:22:29

Trevorw, I have pictures that I added dimensions to. Let me gather them together and I will message them to you. Super easy build actually. All the time was spent figuring out the measurements.

Title: Re: Cafe Conversion "the late night special
Post by trevorw on 08/26/15 at 19:48:18

Awesome! Thank you so much! I really appreciate it!

Title: Re: Cafe Conversion "the late night special
Post by CHANMAN on 02/25/16 at 18:22:09

332335222123282526400 wrote:

Do you still have the measurements and diagram? Also I when to the website you got your rear sets from, what model did you get and do you remember how much they were?

Title: Re: Cafe Conversion "the late night special
Post by scubachef on 03/01/16 at 22:44:37

I do have the dimensions. Shoot me an email address to send them to and I'll get them to you. I got my rearsets from fastfromthepast.com.

Title: Re: Cafe Conversion "the late night special
Post by Happybandit on 04/07/16 at 16:21:54

I would love the dimensions as well. Unfortunately, it won't let me pm you. I hope its ok to connect here. Could you pm me for my email?

Title: Re: Cafe Conversion "the late night special
Post by TBR125 on 12/24/21 at 00:24:04

How have the RFY Air Shocks been working for you? I bought a pair for my scrambler build but one started to stick down with almost no rebound.

Title: Re: Cafe Conversion "the late night special
Post by Gary_in_NJ on 12/24/21 at 04:39:36

Unlike the OEM shocks, the RFY shocks are rebuildable. A simple seal kit (and a good cleaning) is all that is required. By the way, the “air” in the air shocks is nitrogen, so you’ll need to bring ‘em to a shop to top them topped off.