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Thread: Time to build another bike

  1. #1
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default Time to build another bike

    I'm one of those people who can't not have a project of some sort going on, so it was only a matter of time before I bought another bike once I finished my Suzuki build, which involved taking this:


    To this:


    (Build thread: http://www.stanceworks.com/forums/sh...ad.php?t=38839)

    And now my new bike build is officially underway. This weekend I picked up a 1982 Yamaha Virago (XV920). It's in really good condition for a 32+ year old bike, and it only has 10k miles on it.



    These bikes are pretty tragic looking in stock form, but that will change soon enough.



    It hasn't been started in about 10 years, so once I got home, I got right to work tearing it down to clean out the gunk.



    I changed the oil, filter, and spark plugs, then drained the carbs. The bike cranked right over and gave me a little sputter, but didn't want to fully start. I blame that on the dirty carbs and the fact that the battery I was using was too small for the bike and barely had enough cranking amps to turn the V-twin over.

    The Hitachi carbs on these bikes are notorious for being a pain in the ass to syncronize and tune, so I'm not even going to bother. I'm tossing those in favor of a single 40mm Mikuni. Easier to tune, less 'stuff' on the bike, and they greatly improve low end power (at the expense of a little top end power, but I'm okay with that).

    This build will get finished a lot faster than my last one because I'm building this for a friend of mine, and I promised to have it done by the end of the winter (it's actually going to be a surprise for his wife's birthday).

    Plans for the bike are still a little fluid, but the general direction the bike will be taking will be something along these lines:





    I'm excited to get to work on this project because I've been wanting to build a Virago for awhile now. They're such ugly bikes in stock form, but there is a ton of potential hidden underneath all the crappy 80s design Yamaha covered them in.

  2. #2
    Join Date
    Feb 2010
    Location
    Temple, PA
    Posts
    4,397

    Default

    cant wait to see this one. Loved your last build.

    I like the style that you plan to go with on this one.
    Insta Mintyhinrichs

  3. #3
    Join Date
    Jan 2015
    Location
    FoCo, Colorado
    Posts
    275

    Default

    I love cafe racers. Cant wait to see where this goes

  4. #4
    Join Date
    Mar 2012
    Location
    Seattle, WA
    Posts
    492

    Default

    This is bound to be good!

  5. #5
    Join Date
    Nov 2011
    Location
    Clarksville, TN
    Posts
    225

    Default

    I'm in...

  6. #6
    Join Date
    Feb 2013
    Location
    Germany
    Posts
    550

    Default

    In af
    IG: @blk_A45

  7. #7
    Join Date
    Mar 2012
    Location
    Kensington, CA
    Posts
    179

    Default

    Lolz I've got a halfway-done '82 xv920 in my garage too, most likely try to get it wrapped up over the winter as well. You really should be on customfighters, so much good info over there

    In for more
    conversion syndicate*

    4g63 swapped Hilux: http://www.stanceworks.com/forums/sh...ad.php?t=75423

    ig: makercruuz

  8. #8

    Default

    like the style that you plan to go with on this one.

  9. #9

    Default

    in for mikuni and well 80s cafe-racer transformation.

    in case you need some references on fitment and stuff:
    http://www.customfighters.com/forums...ad.php?t=49333
    http://www.customfighters.com/forums...ad.php?t=60761
    Last edited by TeckniX; 09-01-2015 at 10:31 AM.


    "Never argue with an idiot; they'll drag you down to their level and beat you with experience"

  10. #10
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Quote Originally Posted by cruuz View Post
    You really should be on customfighters, so much good info over there
    I lurk over there, but don't have an account currently (I probably should make one). The lime green and black forum layout makes my eyes want to bleed, it's almost as bad as the KAWF format on QuattroWorld. LOL

  11. #11
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Soooo, this might be turning into a double bike build because I "accidentally" bought another XV920 this weekend. It was too good of a deal to pass up.

  12. #12
    Join Date
    Mar 2012
    Location
    Kensington, CA
    Posts
    179

    Default

    Gotta love accidental project acquisition
    conversion syndicate*

    4g63 swapped Hilux: http://www.stanceworks.com/forums/sh...ad.php?t=75423

    ig: makercruuz

  13. #13
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Alright, time to actually start working on these things. Adulthood keeps getting in the way, but I made some time this weekend to bring the bikes inside so I can start tearing them down and get to work. Space is tight, but sometimes you gotta work with what you got.


  14. #14
    Join Date
    Apr 2012
    Location
    Aberdeenshire Scotland
    Posts
    276

    Default

    So in for this
    I am a party pooper. I poop at parties.

  15. #15
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Had an opportunity to slip away from family stuff this weekend and devote some time to one of the bikes.

    Finally got one stripped down to the bare essentials. This is pretty much all I'm keeping from this bike.



    Then I mounted up the Triumph Speed Triple front end. As luck would have it, the Triumph stem works perfect with the Virago head bearings, so I didn't need to spend a bunch of time figuring out a custom bearing solution and/or swapping the stems on the yokes.



    And now to deal with the rear wheel. A huge pet peeve of mine when it comes to custom bikes is when the front and rear wheels don't match. I'm committed to the Triumph front suspension and I'm not giving up the dual 13" 4-pot brakes up front, so that means I'm going to need to come up with a solution for the rear wheel on this bike. Besides, let's just all admit that the factory swirl wheels on these bikes are awful looking.

    After spending way too much time online doing research, I decided that a rear wheel from a 1996 Suzuki Katana is the way way to go. It matches the 3-spoke design of the Triumph wheel, is 17" in diameter, and isn't as wide as most modern sport bike wheels, so it will still fit in the swing arm without being off-center, but will allow me to run a slightly wider tire, like a 150. Also, the rear axle size on the Katana was the same as on the Virago, so that will save me some time in the machine shop when I retrofit the disk brake system. I'll be machining the wheel to accept an adapter for the shaft drive.



    I also ordered a tank from an XV750 since the factory XV920 tank is big and ugly.


  16. #16
    Join Date
    Jul 2010
    Location
    San Diego, CA.
    Posts
    1,683

    Default

    a bike build! this will be awesome judging by your previous bike.

  17. #17
    Join Date
    Jan 2014
    Location
    KZOO, MI
    Posts
    810

    Default

    already looks better with that front end!


    Quote Originally Posted by BozoBubble View Post
    Stance bug bites hard, man, you ain't gonna shake it.

    Truck Build

    Instagram: somestancekid

  18. #18
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    The Yamaha is currently with my friend Rob to take care of some of the welding and fab work that I can't handle myself. Once I get it back from him, I'll hopefully be making a lot of progress pretty quickly.


  19. #19
    Join Date
    Jun 2015
    Location
    Québec, Canada
    Posts
    274

    Default

    im so in for a bike build!
    Ruining cars since 2006 yo

  20. #20
    Join Date
    Sep 2014
    Location
    sydney
    Posts
    258

    Default

    That looks great. Do you have some advice for me looking to fit my '06 675 with a single sided rear swing arm? I have some fab experience with cars but none with bikes. I'm about to read the build thread of your other bike as I spotted you've done it there. I was thinking a 1050 rear end but it doesn't bolt up. Not afraid of making things work, but I wouldn't know where to start haha.
    Last edited by anti.engineered; 01-11-2016 at 07:33 PM.

  21. #21
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Quote Originally Posted by anti.engineered View Post
    That looks great. Do you have some advice for me looking to fit my '06 675 with a single sided rear swing arm?
    The first thing to do is make sure there is enough physical room for the swingarm you want to actually fit on your bike. I made this mistake on my Suzuki when I bought the Triumph rear swingarm and then realized it was a good 2" too wide to actually fit in the frame on the Bandit.

    This is a good thread with a lot of good info about swingarm sizes:
    http://www.customfighters.com/forums...?t=8638&page=3

    The hardest part about fitting a SSSA to your bike is making sure the sprockets are aligned and the wheel is centered (or as close to centered as possible). Don't worry too much if the wheel isn't perfectly centered on the bike, chain alignment is the most important part. You will never notice it if the rear wheel is offset a few mm to either side.

    You might need new bearings or bushings to match up the new swing arm with the existing swingarm pivot bolt. Here's a good place to search for bearing:
    http://www.bocabearings.com/

    I couldn't find the right bearings for the swap on my Bandit, so I ended up machining sleeves out of bearing brass for my bike.

  22. #22
    Join Date
    Mar 2012
    Location
    Kensington, CA
    Posts
    179

    Default

    Lolz I pm'd him the same info. Vxb.com is also an excellent place for bearings
    conversion syndicate*

    4g63 swapped Hilux: http://www.stanceworks.com/forums/sh...ad.php?t=75423

    ig: makercruuz

  23. #23
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    This round of fab work took longer than anticipated, but as usual it was worth it. Rob does amazing work. One of these days I'll have myself a proper shop/garage where I can fab things on my own... but until then Flipside is my go-to.

    The frame was modified so the battery can be hidden under the tank, and a new subframe was made for the seat that also raises the tank a few inches, and changes how it mounts to the bike.









    Next up is making an all-new wiring harness, a bunch more fab work for misc. small parts, fitting the new laced wheels, and getting the thing all put together and running to make sure everything works correctly.

    Then it all comes back apart again for paint/powder/polishing and whatnot.

  24. #24

    Default This...

    Is awesome! I really want to build a bike after I finish my rabbit. Looking forward to updates!

  25. #25
    Join Date
    Nov 2009
    Location
    Renton, WA
    Posts
    561

    Default

    Got the 15x3 XV535 rear wheel machined to accept the Virago drive flange and it bolted right up after swapping the bearings. The hub on this wheel is a little wider than the factory wheel, so I'll need to machine the axle a bit so it can slide all the way through (the spacers are "built in" on the axle on these). Bonus: I have room for a 150mm wide tire in the rear with this wheel, as opposed to the 130 it had stock.



    I ordered a 16x3 wheel for the front, but when it arrived it was actually 17x4.5, so I had to send that back. A new one is on the way now, hopefully the correct size this time...

    The front wheel is going to be a bit of a Frankenstein, but it should be fairly straightforward once I'm done with the machining. The rim and hub is from a Harley Road King, which will be fit to the Triumph Speed Triple forks with some 25mm-20mm axle spacers, then I will need to machine a set of 1st gen Suzuki Hayabusa front brake rotors to bolt up to the Harley hubs, plus some spacers to get the calipers centered on the rotors. You don't see many bobbers with 4-piston, 320mm brakes.
    Last edited by Capt. Obvious; 03-15-2016 at 12:38 PM.

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