500 K cafe racer conversion - build thread

[Ewan 500 K1]

great work Ewan,

 I shall be very interested when its finished and running,

 good luck,and keep us informed !!!

Thanks John, I'm sure there will be a few niggles along the way that I might need to ask the oracle about    Today I realised that I'd left out one of oil o-rings that sits between the cyinder head and the barrels when I rebuilt the top end after I'd been in renewing the piston rings and fixing the cam chain adjuster... so had to strip the top end down again.... bugger

[Ewan 500 K1]

Tonight I thought I'd check the carbs over before bench syncing them. Main jets are 110, pilots are 40 and needles are in the middle groove  and joy of joys ............the wee bolt that joins the carb slide to the lifting mechanism on one of the carbs sheared     ..... more time needed that wisnae planned for 

... luckily I have a  spare carb body I can canabalise if the worst comes to the worst

[simonster]

Hi Ewan,
Your Cafe conversion is looking really good and a great thread too. I like the clubman bars you are using and i'm trying to source something similar. I have researched these to death and all the stock bars don't drop enough and the pull is too wide for the look i want!... Are these a special or off the shelf? cheers.

[Ewan 500 K1]

Hi Ewan,
Your Cafe conversion is looking really good and a great thread too. I like the clubman bars you are using and i'm trying to source something similar. I have researched these to death and all the stock bars don't drop enough and the pull is too wide for the look i want!... Are these a special or off the shelf? cheers.

Hi Si, got them 2nd hand off ebay.  They do clatter off the tank in the position I like, so had to extend the steering stop on the bottom yolk 10cm either way

[simonster]

Hi Ewan,
You must have dropped lucky there. I have now bought two styles of clubman/cafe bars and I'm still not happy how they look. It would help greatly if you are able to measure yours for the width, rise, centre width and pullback of the bars, it may narrow my search for the perfect bars. Thanks in advance! Simon

[cb750stu]

Hi Ewan the bikes looking good so far well done !!

Have you tried the kickstart to make sure it clears everything ?? I fitted the tarozzi rearsets to my 750 and it hits the brake pedal I think I might have to heat it and bend it so it clears, yours may be different though !!

Cheers

[Ewan 500 K1]

Hi Ewan the bikes looking good so far well done !!

Have you tried the kickstart to make sure it clears everything ?? I fitted the tarozzi rearsets to my 750 and it hits the brake pedal I think I might have to heat it and bend it so it clears, yours may be different though !!

Cheers

Hi Stu, I think if I'd used the standard tarozzi mounts there might have been an issue... but I've mounted the sets further back .. on the passenger peg mounts , which is better suited to the guiallari seat riding position. Kikstart JUST clears the brake pedal in this position

[Ewan 500 K1]

Hi Ewan,
You must have dropped lucky there. I have now bought two styles of clubman/cafe bars and I'm still not happy how they look. It would help greatly if you are able to measure yours for the width, rise, centre width and pullback of the bars, it may narrow my search for the perfect bars. Thanks in advance! Simon

Hi Si, been away for a week, will measure up tomorrow and let u know

[simonster]

cheers ewan, no major rush pal.

[Ewan 500 K1]

cheers ewan, no major rush pal.

here ya go .... rough(ish) dimensions.  You seen tarozzi's  adjustable bars  & clip ons ?

http://www.discovolantemoto.co.uk/clipons-65-c.asp

[Ewan 500 K1]

Time to get the 500 four back on the road after a break of three years, this time this time to finish the cafe racer job that was started about 17 years ago

Done : Full Engine rebuild about 3000 miles ago.

To do:
K&N Air Filters (done)
Straight through pipes (done)
Rejet with 110 mains/ clean / syncronise carbs (done)
Rebuild both wheels with new rims & spokes(done)
Dual Disc front brake conversion (done)
Drill front sprocket cover
Remodel Front Mudguard (done)
Drill brake discs (done)
Detag & shorten Frame (done)
Replace stock speedo/ rev counter (done)
Ace Bars (done)
Custom Tarozzi Rear Sets on rear foot peg hangers (done)
Relocate Battery  (done)
Rewire from front to back and everywhere in between (done)
New Headlight (done)
New idicators (done)
New speedo (done)
New rear lights set up
New longer rear shocks (done)
New front mudguard (done)
Polish alloy (done)
Braided Stainless Fuel & Brake Hoses (done)
Stainless Bolts througout (done)
Refurbish Front Forks (done)
New Rear Shock Swing Arm Bushes (done)
New Plugs
Powder Coat the frame
Investigate effect of longer rear shocks on bike geometry and make front end adjustments if necessary (nearly done)
Fit Steering Damper (done)
Fit grease nipples to front break caliper arm pivot points (done)
Tune up carbs
Get MOT, tax and insurance

[Johnwebley]

wow !!

  thats a whole heap of work,


   lets us know how it handles? 

  and how the motor runs

 

[Ewan 500 K1]

wow !!

  thats a whole heap of work,


   lets us know how it handles? 

  and how the motor runs

 

surely cannae be long now    Engine was fully rebuilt about 3000 miles ago, including new primary chain, new crankshaft shells, camchain & tensioner. Ran sweet before the rebuild, though needs a bit of carb fiddling.

[simonster]

Thanks for the bar geometrics... very comprehensive and much appreciated. Keep up the good work with the cafe mogrel.

[Ewan 500 K1]

Tonight I thought I'd check the carbs over before bench syncing them. Main jets are 110, pilots are 40 and needles are in the middle groove  and joy of joys ............the wee bolt that joins the carb slide to the lifting mechanism on one of the carbs sheared     ..... more time needed that wisnae planned for 

... luckily I have a  spare carb body I can canabalise if the worst comes to the worst

Carb sorted, though I had to wreck the lift mechaism roller drilling the remains of the bolt out of it so that the roller could slide out. Replaced that roller with my spare one..... Electrics this weekend. Lost the bloody carmera up a hill on islo skye so nae photies for a bit.