Cafe Bike v 2.0 got underway yesterday, with two students working on the bike. To start, we needed to come up with a different handlebar solution. The clubman bars put the rider's arms too far forward and down to make for a comfortable ride. The handlebar controls needed to be removed, the clubman bars swapped out for the "drag bars" donated by Transcanada, and the control all reinstalled to test fit...
And we still have a problem! Now the drag bars foul on the edge of the fuel tank when they are turned. Need to try something else...
With these old bikes, the forks are known to be pretty spindly and weak. The fender is actually a key component to stiffen up the front end. Removing the stock fender necessitates a fork brace. However the stock fender did not suit the lines of the bike we envision. So what we decided to do is "bob" the fender, shortening it up at the front and the rear. After Mr. S did a rough hacksaw cut, we went about grinding the correct profile. The profile is still rough, so we'll clean it up/finish it off with a belt sander, grinder, file, or a combination of all 3.
With the different handlebars, the front brake line was now too short. We needed to drain the brake fluid out of the front resevoir, reposition the master cylinder, and then measure for the correct length of front brake hose. As we have not determined the final handlebar choice, this is still on hold.
Some electrical investigation was next. Some wiring had already been done, and the battery moved to behind the seat. We needed to check what lights and systems worked and what needed rewiring or reconnecting.
At first glance, things look pretty good. We are missing some indicators, and the turn signals need some work, but the correct wiring is in place and there appears to be little that needs to be rewired. For example the brake light works, but the running light does not. Is it the bulb or the wiring? We'll have to do some digging...
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