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My XJ "Eight Ball" cafe-racer

Discussion in 'XJ Modifications' started by gazzz, Dec 31, 2014.

  1. gazzz

    gazzz Member

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    Hi again! So I decided to create here a thread of my building of XJ cafe-racer .

    I sold my XJ400 in 2007 and expected never to see it again in my garage. But 2 years later this bike returned back to me, being a little bit crashed here, and more than bit smashed there, and in completely non-functioning condition after non-fatal road accident. The former owner (of the bike) knew about my search for custom bike creation base. As a result the disassembled XJ-400 was back, and waited for a couple of years in the corner of my garage, before I started constructing this cafe-racer. Meanwhile, it is a long story, so would you wish so, I could try to give the full version later.

    A little summary information:

    IMG_5705.jpg

    XJ400 4G0 modified frame.

    XJ600 51J engine modified with XJ600 Diversion cylinder block (which has lager cooling fins than stock one ) and manual cam chain tensioner. Ported and polished head channels. Also was rebuilt, polished and custom painted.

    4in1 Sebring exhaust.

    Kawasaki KZ650 fuel tank with QSPS fuel gauge tank cap and Suzuki GS750 fuel petcock.
    Modified Honda XL600R steel swingarm.

    IMG_5789.jpg


    36mm FZ600 front fork with modified air pressure system. Lower triple - XJ600 51J, upper - FZ600.

    Kawasaki Zephyr 750 air pressured fully adjustable rear shocks modified with Honda CB400 Super Four springs.

    Modified rear 17" tubeless spoke Honda XL600RM wheel.
    Tubeless spoke front wheel with 17" Honda XL600RM rim, Yamaha XV750 hub, custom made "Central Wheel" spokes and XJ600 51J brake disks.

    Pirelli MT60 140/80-17 rear tire and Pirelli MT90 120/90-17 front one.

    IMG_5846.jpg


    Yamaha FZ6 front calipers and master cylinder with Hel steel braided brake lines.

    Honda XL600RM rear drum brakes with EBC grooved shoes and custom drive.

    Custom made:

    - front fender;
    - seat (with aluminum base);
    - fiberglass rear tail;
    - electrical box (steel box with aluminum and rubber side covers);
    - footpegs;
    - license plate mount unit and chain guard;
    - aluminum pod filter covers, turn signal mounts, oil cooler mount;

    IMG_5806.jpg


    6 1/4" Bates style headlight. Daytona mini turn lights.

    Custom made rear light unit with hi-power LEDs.

    Acewell "all-in-one" digital dashboard.

    Custom made clip-ons and mirror.

    Motollana fatty 7 pleat fork gaiters with custom lower mounting clamps. Motomi classic grips.

    Custom paintwork.
     
    Last edited: Dec 31, 2014
    wgul and Jetfixer like this.
  2. gazzz

    gazzz Member

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    Under Construction :)

    cafe_all_details_01.jpg
     
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  3. Bigshankhank

    Bigshankhank Active Member

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    Awesome work. If I had to pick a nit, I would question the use of DS tires, but otherwise it is very impressive.
     
  4. a100man

    a100man Well-Known Member

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    Wow ! That's beautiful.

    Interesting to learn that diversion pots will fit a regular 600 engine. Did you keep the chain guides and just use the diversion tensioner ? I'm also looking for a box section swinging arm for 'xj598'. I believe the radian one will fit but they are quite rare in Europe. What mods did you have to make to the XT swinger?

    Well done - looks fantastic.
     
  5. Beekman

    Beekman XJ Grasshopper

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    Great work, looks really awesome
     
  6. gazzz

    gazzz Member

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    Thanks!


    Bigshankhank: Yes, I know. But there are many different directions of cafe-racer’s evolving recently. So this bike was never planned as pure-blooded cafe. The closest style is maybe “cafe-tracker”.


    a100man: That was interesting experience. If shortly:

    - Cylinder head gaskets of both engines has identical part number;

    - Oil channels and dowel pins positions is same on both blocks, so XJ600(FJ600) cylinder base gasket also suitable;

    - Original cam chain guides were kept , but rear one is need to be a little bit modified;

    - Diversion cylinder block and XJ600 crank case also needs to be little hand cut;

    - XJ600 rear cam guide pin's plug need to be replaced by lowered one, so pin will be shortened too;

    - Diversion tensioner became too long for setup and by this reason will be converted to manual mode one with additional body modification.

    Swingarm is XL600R, not XT600.

    - Frame was cut a little wider in axle points (I didn’t precisely measured);

    - Swingarm inner sleeve was bored to XJ axle diameter;

    - Shocks mountings were welded to swingarm.

    But I have no information about adopting stock XJ wheel to this swingarm.
     
  7. Kickaha

    Kickaha Active Member Premium Member

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    They're the only thing that look a bit out of proportion to the rest of it

    One of best conversions I have seen
     
  8. a100man

    a100man Well-Known Member

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    Ah OK . I wondered if it could be done with the bottom end in tact but if you had to widen the crankcase I guess you had the engine apart. Correct ?
     
  9. gazzz

    gazzz Member

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    a100man: No, you don’t need bottom end' separation. It’s hard to explain all that thing with my English knowledge. But I’ll try to explain it with a few pictures.

    All modifications that I made were related to difference between slope angles in the cylinders. Diversion cylinder block’s angle is lager then XJ600 one. So, when you try to put Diversion block on XJ bottom, you see that the rear part sits right on the pin plug of rear tensioner.

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_1771.jpg

    You can cut a bit of cylinder block in the tensioner area, but that’s not enough, you need more low plug:

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_1921.jpg

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_2055.jpg

    Also you need to cut a bit of crankcase surface in order to get access to operate with the tensioner: for instance, to install the tensioner, and to tighten its lower mounting point.

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_1990.jpg

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_2082.jpg

    All that things were installed more close one to another, but it works after all.

    You may find below the photo of modified rear guide.

    http://moto.kiev.ua/users/gazzz/cafe_project/xj/part5/IMG_2129.jpg

    As you can see, it’s just a contact point lowering.

    I didn’t make a modified tensioner' photo. I may take it later, if needed.
     
    Last edited: Jan 1, 2015
  10. Skwerly

    Skwerly Member

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    And here I was thinking how neat the tires looked. :D This is super cool.
     
  11. Orange-n-Black

    Orange-n-Black Well-Known Member

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    I don't think there's anything on this one to dislike. IMO Good job, looks fantastic.
     
  12. a100man

    a100man Well-Known Member

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    Many thanks for the detailed description. Diversions are common here whereas the xj600f is less so . and bores are often worn
    or rusted - good to know there's another option to refresh the top ends ! Thanks again.

    James
    '
     
  13. gazzz

    gazzz Member

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    Thanks, I am glad you like it.

    a100man: Not at all, I've got the same difficulties.

    And I think it's time to post some detailed photos:

    IMG_6060.jpg

    IMG_5878.jpg

    IMG_6032.jpg

    xj_cafe_details_02.jpg

    IMG_5625.jpg
     
  14. gazzz

    gazzz Member

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  15. gazzz

    gazzz Member

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    I hope, I haven't bored you:)

    IMG_5563.jpg

    IMG_6221.jpg

    IMG_6199.jpg

    IMG_6196.jpg
     
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  16. FtUp

    FtUp Well-Known Member

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    nothing boring about your work. I love the 8 ball graphic on the tank, the way it is all snap rings. I also love that oil temp guage. where can I find me one of those? the chain link foot pegs are cool too.

    CN
     
  17. kwes

    kwes Member

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    i think i'm in love!
     
  18. Smit

    Smit New Member

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    this is an inspiring work of art gazzz, how many hours did you clock in? ;)
     
  19. ShinySideUp

    ShinySideUp New Member

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    Absolutely sick. Seriously, nice work and pics.
     
  20. gazzz

    gazzz Member

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