Wednesday, January 27, 2016

Identity Crisis

The eagle-eyed viewers will notice we've gone from Cafe, to Scrambler, and then back to Cafe again... it's all about the bars.
We've been struggling a lot with bar-tank interference.  The lower bars and the steering lock is such that at "full lock" the bars hit the front of the tank.  Other cafe-d CX500s use a different tank, but sourcing those tanks is difficult, and they carry a premium price.  So instead, we decided to go back to Cafe Bars which helped somewhat with the clearance issue, but we still need to massage the fuel tank to allow the bars to be turned a safe amount.
I prefer this racier stance for sure, but you can see the "dimples" just aft of the bars.  Judicious use of a ballpeen hammer has allowed for enough clearance.  The tank will be repainted, and hopefully a guru at the pant shop can maintain the clearance and make the dimples look like they are supposed to be there.  There aren't a whole lot of hammer marks anyway, so that's positive.  The sheetmetal was thin enough that it didn't need to be beaten too severely.

The OEM-style fork dust boots were also installed.  The gaiter style accordion boots didn't fit very well.  The fender is pretty substantial -- we actually had to remove the forks after this picture, install the fender, and then reinstall the forks in the triple clamps.  Forks of this era aren't the sturdiest, so the fender acts as a brace.  It's not super heavy, but is stiff -- what the front end certainly needs.

The front view.  The front fender sits a tad high, but other than that, it looks OK.  A lot of the wiring will be the next step, along with finalizing the exhaust mount.  We'll be installing a period-correct, but uprated, front caliper to these forks to improve the stopping power of our hopefully quicker machine.  The front disc is also a lighter EBC unit.  We've been talking as a group about the benefits of reducing rotating/gyroscopic mass.

Friday, January 8, 2016

On yer feet!



Back at it.  First step was to get the front forks installed into the triple clamps.  The forks themselves were rebuilt awhile ago.  They were still oil-tight, but the fork "gaiters" (the accordion dust seals) look a bit worse for wear.  We might have to replace them before we give the bike away.

The wheel went on next, being sure to include the spacer on the right, and the speedo drive on the left.




We test-fitted the exhaust headers, and realized the exhaust bracket that was rough-fabbed last year needed to be cleaned up.  First some work on the grinding stone to get rid of sharp edges, and then off to the wire wheel to prep it for paint.










At session's end, starting to really look like a bike again.  We need to do some painting, and track down some rubber bushings (that are no longer available... Mr. S will hit up some of the interweb forums for help).  We'll be able to finish off the exhaust, add the carbs, and start re-routing the wiring.  I think we've timed the current "scrambler" craze just perfectly!