How to build an XV750 Cafe Racer
I am going to log the progress of my XV750 café build so every one knows how to do it.
This is how my bike looked when I got it. Pretty nice a shame to chop it up.
The first job is to stock the fridge.
Next set you bike up. I use a bike lift to make things a bit easier on my back.
Now before the questions come rolling in, I have already built myself some wire wheels. I will get to that one later.
Also I have played around with the muffler
Ok time to start ripping it down. Tank, seat, side covers and battery are first for me.
Start to un plug the wiring at the back of the bike. Make sure you label everything even if you think you can remember the most basic things like + & – to the battery label it anyway, in a few months time when it comes to putting it back together you will be glad you did. and it will save you a trip to the auto elec. Take lots of photos as well.
Foot pegs, brake and clutch peddles are next to go.
Next I removed the handle bars and the whole back sub-frame.
Next to go was the gauges and headlight, there are a lot of wires in the headlight so label, label, label.
If you haven’t had a beer yet then its time to crack one, you deserve it.
After all this you should end up with a big pile of stuff to sell.
Next I removed the exhaust, rear wheel and swing arm
And the shock
Time to get the frame and front end off all in one
Remove the forks and she’s all in bits.
Now its time to clean, polish and paint. This is the most boring job but also the most important to get good.
Cut corners here and the finished bike will look good but not perfect.
I have taken the forks apart for a paint and some new seals.
Got the fork legs back together last night. New seals and a good clean up
I am working on making a manifold to fit up some Mikuni VM34 carbs to get the thing running a whole lot better.
The prototype is looking good.
I soda blasted the engine and now its ready to paint.
The motor is all painted and ready to go
All the frame parts have now been sandblasted and painted.
Time to start the re assembly
Frame and swing arm are now on
Now the forks, front wheel and subframe.
Headlight and bars are now on
Rear wheel was next (Now we are rolling)
A bit of beer bling
Well I’ve done a bit of work on the right side of the bike.
Hooked up the exhaust, polished up the engine cover, replaced all the bolts with stainless steel and got the rear brake set up.
Got the bendex spring fixed, a new clutch cable fitted and the gear shift sorted. Now the shift is upside down race style. That will take a bit of getting used to. Still have some polishing to do.
I have fitted up a carbon front guard of a busted R1
I have repainted the brake components.
Now its time to fit these up and start work on the front of the bike
I have now rebuilt the brake calliper and fitted the brake lines which I need to get a shorter one as it is way to long, you get that when changing from cruiser bars to clip-ons.
I have also fitted up the throttle cables I used the right hand switch block and cables from an XS650 purchased from Mikes XS http://www.mikesxs.net/ a great place to get late 70’s early 80’s Yamaha parts.
A few more bits n pieces to do then its time to get stuck into the wiring nightmare.
So the bars are now fully loaded just need to bleed the brake
Now its time for the wiring nightmare
Got the wire roughed in so I fired it up with a makeshift tank.
Di you know you can use a coke bottle to fill your oil, funny they have the same thread just screw it in.
Well after a serious headache I finally have the wires sorted and all I need now is a tank and I’m done.
Ok so I went nuts and made myself a carbon fiber tank pleas don’t ask for one as this is a one off. If your after one you will have to make a decent offer on the whole bike.
Well its all done and I am very happy with the result. Cheers Twig
Nick made a short YouTube of the finished bike check it out.