SuzukiSavage.com - Cafe Build

ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #15 - 05/18/19 at 10:45:11 http://imgur.com/a/9z79Ap6 Progress on the seat pan and fuel gauge mount.
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ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #16 - 05/18/19 at 16:55:51 http://imgur.com/a/Vxh2kfr How do these look Ohiomoto?
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Cafe Build Reply #17 - 05/18/19 at 18:31:33 I think I would have waited on the seat pan until the mid controls were built , so that the tail of the pan ,could be sized and your body positioned for the most comfort , as a café bike has the least to begin with.
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ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #18 - 05/18/19 at 19:19:39 Im going to rock the forwards for now, at 6'2 theyre essentially mids for me 😐
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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Cafe Build Reply #19 - 05/18/19 at 21:30:51 That could be a problem if you've lowered the forks, lots of footpeg grinding.
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ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #20 - 05/19/19 at 04:02:22 Oooh good point. Haven't lowered the front end,I'll report back on this after first ride
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Re: Cafe Build
Reply #21 - 05/19/19 at 04:22:11

Great fiberglass work. The bike is looking good.

When I built my bike, I did the tank, seat and rear fender and then set my pegs where they needed to be. I also rode my bike with lower forks and stock pegs for a summer with very little peg grinding. That said, you can't leave forwards on a cafe... that's just wrong!

Welds are getting better. First one is still a little cold, but it's a harder weld to do as it needs a lot of fill. The rest look better. Keep practicing.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 4997 Manteca , CA Gender:	Re: Cafe Build Reply #22 - 05/19/19 at 04:50:45 If I have to weld something thicker than normal I'll preheat the metal pieces then my 110 volt welder doesn't struggle
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ZSteele

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Re: Cafe Build
Reply #23 - 05/19/19 at 09:09:47

Eventually I might actually go with rearsets but Id like to get the bike functioning first 😉 still waiting on electronics but theres plenty to finish up until then

I need to go over the hump again with bondo, theres some funky flat spots. Also gotta get the tray, side panels, and under hoop bat storage cut and welded. Once thats all good I can finish the seat mounting and get on with upholstery.

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ZSteele

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Re: Cafe Build
Reply #24 - 05/23/19 at 14:34:46

Got the majority of the electronics in but still missing 2 key things before I start wiring. In the mean time I have plenty of welding and upholstery to do. The new headlamp uses fork tube clamps for mounts, would it be easier to take the whole top triple clamp off to slip them on or loosen the bottom triple and slide the assembly down away from the top triple? Planning on replacing fork oil soon but Id rather not disassemble that section entirely until the bike is more put together.

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ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #25 - 05/23/19 at 14:38:50 Sike, one youtube vid later it looks like loosening the bottom triple and removing the 2 top nuts is the way to go. Ill post again when I have some work done.
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SpamyToo Full Member Offline Posts: 231	Re: Cafe Build Reply #26 - 05/23/19 at 21:36:40 You already have the headlight mounts? There are several out there that are two or three peice you can put on without taking the clamps off. Also some are sheet metal that you can bend open and then push on without the hassle.
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ZSteele

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Re: Cafe Build
Reply #27 - 05/24/19 at 05:01:01

Already got them, no biggie though. Like I said, I do want to refresh the fork oil so this'll be a good start to feeling comfortable mucking with the triple tree. Ive noticed that most of the time I start disassembling/fixing/modifying a section of the bike it's uncomfortable the first time, but once I've gotten through it once it's no biggie the second time round.

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Re: Cafe Build
Reply #28 - 05/24/19 at 05:41:17

ZSteele wrote on 05/23/19 at 14:34:46:

The new headlamp uses fork tube clamps for mounts, would it be easier to take the whole top triple clamp off to slip them on or loosen the bottom triple and slide the assembly down away from the top triple?

Taking off the top triple clamp is pretty easy - but you have to put a support under the frame to support the bike.......as you have to remove the fork caps and that will remove the spring support for the front end.

1) Put supports under the bike.
2) Remove the fork caps....be aware there is some pressure on the springs and the cap will want to fly off.
3) Remove the center nut on the steering stem.
4) Put a towel on the tank, pull the top yoke off and rest it on the towel (or get a friend to hold it).
5) Install your headlight brackets.
6+) Put everything back together.

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ZSteele Senior Member Offline I'll finish it tomorrow Posts: 253	Re: Cafe Build Reply #29 - 05/24/19 at 06:32:59 That doesnt sound too bad either, the bike is already on a jack, I'm guessing in that case just remove fork caps and center nut?
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