79 Special Cafe Custom Build Progress

[WMarshy]

No access to the oil filter!

If hes buildin his own and made it 4-2-X-2 then he could make it so the filter was accessible ...

[skids]

I am excited to see how it comes out.

[poodog]

Your progress is sweet! I'm very interested in the custom exhaust I'm wanting to do something similar due to 4-1s being incredibly hard to find for a reasonable price.do you have any more pics?

[jrobertfox]

Your progress is sweet! I'm very interested in the custom exhaust I'm wanting to do something similar due to 4-1s being incredibly hard to find for a reasonable price.do you have any more pics?

All the photos that I have are found here https://plus.google.com/photos/10977...95463240538049

I guess it was cost effective all things considered, maybe $220 in stuff? Muffler and collector was about a hundred, 60 for the exhaust wrap, 15 for the old school flanges off ebay and the rest for odds and ends.

Of course if you factor in the time building it, its never cost effective :P

But it has the exact fit and finish that I want. I'll try to take a few pics of it on the bike soon. Looks good.

[JackBurton78]

Exhaust

Would you be able to reproduce your exhaust build? I'm needing to redo mine due to the previous owner doing a real hack job repair.

[dondons1984]

I think earlier in the thread he has his drawings for it.

[xs650man]

Re your battery box, did you rubber mount it to those brackets ? I heard vibration kills batterys fast, any thoughts ? Nice build BTW

[jrobertfox]

I wish I could say yes to building one of those exhausts, but I have neither the time nor the workspace for that at the moment. Perhaps in the future I'll have a proper shop and some helpers to make things like that happen.

Regarding the battery box, yes it is gonna sit on two 1" rubber mounts and then be affixed to a cross member with 3/4" rubber mounts, most of the electrics too are gonna be on rubber washers, with grounds as needed.

I was able to get the brakes on yesterday as well as a few more odds and ends. QUESTION!? Anyone know how to adjust the rear brake mount so that the disc does not rub against the mount? Maybe I need to push the wide end of the wheel rod farther out of the clamp or something...

Tank should be done finally next week (had to have some rework done on the stripes to make them more to my liking) And it's gonna look awesome.

Should be able to order the last batch of stuff soon (brake lines, some fasteners, etc) and still waiting on the seat/grips/belt for battery.

Here is a pick with the exhaust on the bike:

[Slow Hand]

Looking good!! You are doing some wonderful work to your bike! Wish I had the time and tools to do similar to mine! I'm just a hack with a grinder and a welder!!

[DiverRay]

If the rotor is rubbing on the brake mount, you have the wrong shims for the type of wheel. The 17" Standard takes one set of shims, and the 16" Special takes another set.
One fix is to use 1/4" flat washers or spacers under the rotor. IIRC it takes two flats per bolt to space properly. The other way is get a flat washer that will fit the axle, and space the brake with that. I think I was able to get "spacers" that fit from Ace Hardware, and I used two of them.

[madmax-im]

before you committ to that exhaust you might want to check it for ground clearance when the bike will be leaning to the right...I had a Jardine 4to 1 exhaust and it dragged on even the slightest lean...and your setup looks pretty much like it would do the same...

[duc]

any updates? build seems great so far

[jrobertfox]

any updates? build seems great so far

Not much just yet, all the rest of the final parts came in, still waiting on the tank and the seat, although they appear to be nearly done.

Got some awesome brake lines from HEL (Black on Black), a bunch of final bolts and washers, and random electrical connectors.

I recently started tracking the project in Trello... and figured, why not just make the board public: https://trello.com/b/GyQoZhMO/xs1100-project

Hoping to get out this week and finish "putting on" everything and start wiring it all together.

[jrobertfox]

Today:

• Installed headlight which was a pita
• installed sick hel brake lines
• test fit the battery box
• mocked up the wireing harnes
• fixed the spacing issue with the rear whele
• made a custome breather vent
• added a threaded sleave to the front wheel spinny thing for the acewell spedo pick up
• mounted the bomb ignition coils

[Slow Hand]

Looking good. Those wires are cool!