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79 Special Cafe Build

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  • #16
    Headlight Relay

    I tried to clean up the tank that I bought and apparently there is more rust than I thought and it had a couple rather large rust holes. So I had to take it to a radiator shop to have them repair and clean it.

    I am finishing up the wiring and I removed the RLU and the stock headlight relay, so I am looking to use this relay: http://www.amazon.com/gp/product/B00...=ATVPDKIKX0DER to run the headlight. I plan to use the heavier gauge wiring from the main switch (as I am relocating it to under the seat pan) and running it from the fuse block to the relay and have the headlight run off heavy gauge wire from the relay to provide more power. I would use one relay for the low beam and another for the high beam, so that both would be on when the high beam is on, and have the low beam triggered off the generator.

    Am I missing anything?
    Last edited by spayne83; 04-27-2013, 07:59 PM.
    79 SF 3H3 Engine, 145/45 Mikuni Jets, El Cheapo Pod Filter Mod w/ EMGO Pods, Coil Repower w/ Dyna Coils, Accell Wires and Side Gapped Plugs, 78 Mech Advance, 4-2 Turnouts

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    • #17
      Originally posted by spayne83 View Post
      I would use one relay for the low beam and another for the high beam, so that both would be on when the high beam is on, and have the low beam triggered off the generator.

      Am I missing anything?
      That will drastically shorten the bulb life if you try to run both high and low beams at the same time....
      Fast, Cheap, Reliable... Pick any two

      '78E original owner - resto project
      '78E ???? owner - Modder project FJ forks, 4-piston calipers F/R, 160/80-16 rear tire
      '82 XJ rebuild project
      '80SG restified, red SOLD
      '79F parts...
      '81H more parts...

      Other current bikes:
      '93 XL1200 Anniversary Sportster 85RWHP
      '86 XL883/1200 Chopper
      '82 XL1000 w/1450cc Buell, Baker 6-speed, in-progress project
      Cage: '13 Mustang GT/CS with a few 'custom' touches
      Yep, can't leave nuthin' alone...

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      • #18
        Duly noted. I am going to wire a kill switch for the lights so that they don't draw power when cranking.

        I also thinking that since I am going to a power switch instead of the key that I need to extra security. I am ditching the horn and I want to wire the pink wire from that button to the ground on the start button so that both will have to be pressed in order for the bike to start.
        79 SF 3H3 Engine, 145/45 Mikuni Jets, El Cheapo Pod Filter Mod w/ EMGO Pods, Coil Repower w/ Dyna Coils, Accell Wires and Side Gapped Plugs, 78 Mech Advance, 4-2 Turnouts

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        • #19
          Running and almost finished

          Made a lot of progress this long weekend. The carbs are rebuilt and the bike runs. I still need to sync the carbs to allow it to run properly without having to hold open the throttle. I cut out and mounted the seat pan and finished the wiring. I promptly broke my main switch trying to bend the connectors so that they would clear the seat. Then I tried to solder the connectors back on and apparently melted something internally, so I am waiting on a new switch.

          I also blew a fuse after replacing the switch and it looks like one of the wires going to the generator had melted through and was grounding on the engine, so I will need to replace it and make sure to keep it away from the engine.





          This is how I am planning on mounting my seat. Those are flexible pipe caps to maintain the spacing under the seat for the electronics. I still need to have the rear hoop welded on to provide some support to the back of the seat and seat pan. Not sure exactly how to mount the back end of the seat though, since it is a curve.

          79 SF 3H3 Engine, 145/45 Mikuni Jets, El Cheapo Pod Filter Mod w/ EMGO Pods, Coil Repower w/ Dyna Coils, Accell Wires and Side Gapped Plugs, 78 Mech Advance, 4-2 Turnouts

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          • #20
            Weekend Update

            Finally got some work done this weekend. I re-cleaned and re-jetted with 145 mains and 45 pilots using genuine Mikuni parts. There was a difference between the pilots that came with my K&L kit and the Mikuni ones, so I don't know if that was causing my problem or not. I also did the El Cheapo Pod Filter mod and changed the spark plugs for BP6ES plugs (I was using Autolites). Here is what those plugs looked like:

            #4


            #3


            #2


            #1


            So it looks like 2 and 3 were running rich with 3 running crazy rich. I also saw black residue in the #3 carb and on the throttle plate

            I set all of the floats to exactly 25.7 mm and I checked to make sure that both sides were reading the same. I bench synced the throttle plates to where they are at the bottom of the first hole of the set of three at the top of the carb. I set the idle mixture screws to 2 turns out from finger tight and used this:
            http://www.amazon.com/gp/product/B00...?ie=UTF8&psc=1 to set the idle to 1100. Good news is that she will now idle without having to hold open the throttle. It requires a lot of finesse to get the bike rolling from a stop and quite a bit of throttle. The power is ok up to about 2-3000 but then flattens out and starts backfiring after that.

            Definitely need to adjust the idle mixture and sync the carbs, but I fear that I may be running too large of jets. Idk if the backfiring in the higher range can be resolved with the mixture screws or if I need to lean out the needle jet. But I saw the same problem with the other jets, so I am not really sure why I would have the same problem with two different sized main jets.
            79 SF 3H3 Engine, 145/45 Mikuni Jets, El Cheapo Pod Filter Mod w/ EMGO Pods, Coil Repower w/ Dyna Coils, Accell Wires and Side Gapped Plugs, 78 Mech Advance, 4-2 Turnouts

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            • #21
              It's been a while since I updated this thread. I'm making some progress, I got it running decently but there is a bog between 4500 - 6500. Then I slimmed down the seat and installed emgo megaphone mufflers. I'll take it out tomorrow to see how it does with the 2" exhaust. Here are some pictures of the work









              79 SF 3H3 Engine, 145/45 Mikuni Jets, El Cheapo Pod Filter Mod w/ EMGO Pods, Coil Repower w/ Dyna Coils, Accell Wires and Side Gapped Plugs, 78 Mech Advance, 4-2 Turnouts

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              • #22
                looking real sweet.
                79 F
                Previously owned: (among others)
                1969 Harley- Davidson Rapido 125 (Aermacchi)
                1967 Suzuki X6 Hustler
                1973 Suzuki TM 125
                1979 XS1100 F
                2005 Kaw. Vulcan VN800
                1991 BMW K75

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