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RobbieRobot Cafe Racer Project in pictures

Discussion in 'XJ Modifications' started by RobbieRobot, Jul 16, 2013.

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  1. RobbieRobot

    RobbieRobot Member

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    1982 XJ650 4K0 (UK Model)
    This is the bike as I bought It.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #1
  2. RobbieRobot

    RobbieRobot Member

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    Arriving Home
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #2
  3. RobbieRobot

    RobbieRobot Member

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    Teardown begins.[​IMG]
     
    RobbieRobot, Jul 16, 2013
    #3
  4. RobbieRobot

    RobbieRobot Member

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    Carbs stripped and cleaned, fresh petrol and she runs.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #4
  5. RobbieRobot

    RobbieRobot Member

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    Continuing teardown.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #5
  6. RobbieRobot

    RobbieRobot Member

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    Engine Out.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #6
  7. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #7
  8. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #8
  9. RobbieRobot

    RobbieRobot Member

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    First stage of engine preparation - steam clean
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #9
  10. RobbieRobot

    RobbieRobot Member

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    Hours and hours of scraping, rubbing and buffing with a Dremel.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #10
  11. RobbieRobot

    RobbieRobot Member

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    Yes. It has a right hand casing upside down on the left side, and badly scuffed and scraped.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #11
  12. RobbieRobot

    RobbieRobot Member

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    Dremel marks all over.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #12
  13. RobbieRobot

    RobbieRobot Member

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    Clutch out for overhaul.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #13
  14. RobbieRobot

    RobbieRobot Member

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    Frame stripped.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #14
  15. RobbieRobot

    RobbieRobot Member

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    ...and de-lugged

    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #15
  16. RobbieRobot

    RobbieRobot Member

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    Corrosion evident.

    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #16
  17. RobbieRobot

    RobbieRobot Member

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    Repair plates prepared.

    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #17
  18. RobbieRobot

    RobbieRobot Member

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    Welded and dressed.

    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #18
  19. RobbieRobot

    RobbieRobot Member

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    All wheel bearings removed.

    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #19
  20. RobbieRobot

    RobbieRobot Member

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    Ready to go for powder coating.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #20
  21. RobbieRobot

    RobbieRobot Member

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    Meanwhile engine starts to come apart.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #21
  22. RobbieRobot

    RobbieRobot Member

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    Off with it's head.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #22
  23. RobbieRobot

    RobbieRobot Member

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    ...and barrels.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #23
  24. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #24
  25. RobbieRobot

    RobbieRobot Member

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    Frame and wheels etc. powder coated.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #25
  26. RobbieRobot

    RobbieRobot Member

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    Some of the new wheel, swing arm and steering head bearings and seals.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #26
  27. RobbieRobot

    RobbieRobot Member

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    In Bits
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #27
  28. RobbieRobot

    RobbieRobot Member

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    Steering head and swing arm back in.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #28
  29. RobbieRobot

    RobbieRobot Member

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    Lapping the valves.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #29
  30. RobbieRobot

    RobbieRobot Member

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    The seat shell.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #30
  31. RobbieRobot

    RobbieRobot Member

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    New Bridgstone tyres, (yes that's the English spelling) gaskets, Brembo brake pads, new rear brake shoes, right handlebar switches from a Suzuki GSXR SRAD 600, left switches from a Suzuki GSF1200 Bandit, clip-ons from a KAWASAKI ZX9B etc
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #31
  32. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #32
  33. RobbieRobot

    RobbieRobot Member

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    Engine etch primed.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #33
  34. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #34
  35. RobbieRobot

    RobbieRobot Member

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    Engine sprayed aluminium silver.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #35
  36. RobbieRobot

    RobbieRobot Member

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    Barrels sand blasted and re-assembled.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #36
  37. RobbieRobot

    RobbieRobot Member

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    Head sand blasted and re-assembled.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #37
  38. RobbieRobot

    RobbieRobot Member

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    Camshafts aligned.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #38
  39. RobbieRobot

    RobbieRobot Member

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    Wiring removed from block connectors to allow new heat-shrink tubing to be fitted.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #39
  40. RobbieRobot

    RobbieRobot Member

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    Bucket shims checked and adjusted and rocker cover back on.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #40
  41. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #41
  42. RobbieRobot

    RobbieRobot Member

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    Tyres fitted.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #42
  43. RobbieRobot

    RobbieRobot Member

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    Fork lowers sand blasted then re-assembled with new seals and oil.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #43
  44. RobbieRobot

    RobbieRobot Member

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    Engine ready to go back into frame.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #44
  45. RobbieRobot

    RobbieRobot Member

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    Engine back in frame.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #45
  46. RobbieRobot

    RobbieRobot Member

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    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #46
  47. RobbieRobot

    RobbieRobot Member

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    Re-assembly.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #47
  48. RobbieRobot

    RobbieRobot Member

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    Mollie's not impressed, she just want's to play ball.[​IMG]
     
    RobbieRobot, Jul 16, 2013
    #48
  49. RobbieRobot

    RobbieRobot Member

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    She's rolling.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #49
  50. RobbieRobot

    RobbieRobot Member

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    Further assembly.
    [​IMG]
     
    RobbieRobot, Jul 16, 2013
    #50
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