PAINT AND ETC. (PART 1)

I'm a little behind on my posts right now, so here's an update on a few things that happened with the bike over the past few days; this post'll be a two parter.

First off, I started painting components. I decided on a Rustoleum Satin Black since my buddy just did his Sportster with it and it looks sick. Rather than tear down the whole bike, though, I decided to paint as many parts as I could in place. I pulled out every rag and sheet of packing paper I could find and started wrapping up everything I didn't want painted.

Here's the setup for painting the tank- note the use of an empty organic chicken feed bad to cover the crankcase. Profesh.

 
The tank came out nice, I think. I debated whether to leave the lettering chrome, but a lot of the finish was flaking off so I just sanded everything a bit and blacked out the whole thing. The paint on the back of the tank was pretty cracked in spots, but the satin fills it out ok... it might not look professional, but it does look badass, which is what counts, right?

The gauges sucked. When I took off the speedometer one of the mounting bolts came loose and fell into the case. I had to take the whole thing apart to get the screw out and put it back on the correct hole. So after an hour of screwing around with that (and the rubber facemounts that disintegrated and the almost slack-less cables, etc.,) I was able to 'mask' them off from the rest of the front end shoot them. Then I did the bars brake levers and lever mounts, top of the triple tree and the headlight bucket, leaving the ring around the lens chrome. I'm still deciding whether or not to do the fork ears and boots... Suggestions? 

the finished (for now) front end

DAMMIT.

Just a quick update on the bike this morning; in an earlier post I mentioned that I took off a broken horn and blinker controls... Well, turns out that this particular set of controls also ran the headlight. I missed this fact since the guy who owned the bike before me also installed a hi-lo beam switch on the frame. Confusing. I only left about 1/2 inch of wire in the switch box when I cut everything out, and fortunately I was able to VERY carefully connect the wires back together. Now my problem is that I'm not sure I can get the box back on the bars, so I might have to tape it all up, leave it on low beam and tuck it into the headlight bucket; I guess I got lucky with that extra switch on the frame. This was definitely my FML moment for the weekend.

XS 850- TEAR DOWN AND DESIGN IDEAS

I figured the first thing I should do is make the bike rideable and as safe as possible, so I decided to start with the rear brake. I've never worked on disk brakes on a motorcycle, and my experience with them on bicycles has been limited to cable controlled, not hydraulic. The problem was that the brake would stop the rear wheel but only back off very slightly when the brake was released, causing some very noticeable friction. I wasn't quite sure what was happening inside the caliper. But that's what the internet is for, right? I started watching some instructional vids on how to free a stuck piston; however, most of them recommended taking the brake to a shop, or buying a rebuild kit. I figured, though, that a combo of common sense and Firestone DBA was all I needed. 

My buddy Karl came over and, seeing as he had never worked on hydraulic motorcycle brakes either, we figured between the two of us we should be able to fix it easily. After both of us put flathead screwdrivers worrisomely deep into our respective palms, we decided it was time for a new plan. Karl pulled up some more videos on his iphone, and we agreed the best plan of attack would be trying to push out the piston with compressed air. My compressor decided it was too tired to help, so after giving up on that, Karl pulled the end off my bicycle pump and attached the rubber hose to the bleed nipple. He gave it 2 pumps and the piston shot out immediately, almost snaking one of my fingers. Underneath, the seals were soft and in great shape, so I cleaned all the corrosion off the piston with some brake fluid, reassembled the who thing, and mounted it back on the bike. We bled the line (another thing neither of us had done) and called it a night after testing what is now a smooth, correctly operating rear brake. I'm going to buy a new rotor at some point, as this one is pretty bad, but at least it stops well and doesn't lock up.

Next I started taking shit off... anything I don't absolutely need is going: rear fender (soon to be bobbed... somehow,) blinkers, passenger pegs, broken horn and blinker control assembly, running lights, old sponge grips, etc.. I also started cleaning, got rid of the wasps and most of the spiders, and started Google searching for design ideas. I don't like cafe' racers all that much (although some are definitely cool); it's not really my style. Since this bike is already a beefcake, I don't think it makes much sense to try to get it too slim. So I'm thinking lean and mean, but not anorexic and bitchy. After some searching, I found this pic:

I don't know who built this bike (it comes from an online used vehicle database) but as soon as I saw it I knew that this was the style I was looking for. I recently met a dude at a poker run my band played who has a Street Bob set up in a similar way and it looks badass... so I'm using this as a template. I like the satin black with tasteful chrome highlights, and I like the short rear end. I also think the black mags are killer. The gauges sort of create a little extra hight in front too. 

So I've got my inspiration. But I think I can make my bike look better than this one. For one thing, it needs a rear fender that comes up past or flush with the back of the seat, and I don't like the tank he used... the stock one looks better (even though it's a goddam whale.) So here we go; next post, new paint and new, lo-pro seat mounting.

UH OH. XS 850 PROJECT BIKE!

It's been a bit since my last post, mostly because I finished the SL125 (dubbed the "Nazgul") and haven't had anything to do (except work 55 hours a week.) Lately, though, I've been itching for a bit more power and reliability than the Nazgul can deliver. This is probably the fault of my buddy who lets me take his 883 Sportster for a spin every now and then. I even started thinking about dropping an old 250cc motor in that little frame (which I have been told, categorically, is a bad idea.) But a few weeks ago I was helping my friend's dad clear out his garage and (cue singing angels) lo and behold, in the back, covered in spider webs (and, as it turned out, filled with wasp nests) was this 1980 Yamaha XS 850.

                                                                   




The bike had technically been for sale for a while, and had been sitting for about 3 years, so the owner was anxious to get rid of it. I payed $500, loaded it into the trailer, and that was that.

I got her home and took a quick ride around the block before the battery died, and the motor runs fine considering it hasn't been started for a long time. I'm used to the Nazgul (top speed, 55mph) so when I hit 60 in second gear I realized... this is going to be fun.

The XS 850 is a sweet bike. Shaft drive, 3 cylinder, dual front rotors-- all power and BEEFY. Check out the size of that tank! Usually these bikes either get restored as close to original as possible, or they get cafe'd out. I'm not sure what to do with her yet; the first order of business is to clean her up.

Obviously, she needs some work. A new battery was a must, as the old Wal Mart special was refusing to recharge and blowing fuses.  Also, the rear brake was stuck, and, unfortunately, had been ridden that way for what looks like a long time, judging from the glacial tills in the rotor. The whole thing is riddled with spiders, and there's a lot of corrosion and rust so most of the components could use a good scrubbing and probably some paint of some sort. The seat is giant, so if my feet are going to even get close to reaching the ground she's going to need a new, lower profile saddle, too, at the very least, and maybe shorter rear shocks.

Next post, I get at that rear brake, start slimming her down, and begin brainstorming design ideas.