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Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in progr

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Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in progr

PostAuthor: rantingsmith » Sun Jun 03, 2018 2:18 pm

Continued from viewtopic.php?f=124&t=28376&start=80


faffi wrote:Probably. Here is the cast rear wheel off the VF750 Sabre, a 3.00x17. It even has drum rear brake.

https://www.ebay.com/itm/HONDA-VF700S-V ... 1387985163

The other 17in shaft drive wheel I can think of that is comstar must be that of the Gold Wing, 1000 and 1100. Oh, and the Turbos. The GL1100 and the Turbos share the flanges, but the 1000 is different. You can also get those with 17in wire wheels.


Well it would not necessarily have to be a 17" but it would have to be one of the riveted type comstars as they are relatively easy to convert to spokes.. as in two laser cut rings with corresponding holes some spokes and rim of choice..

See here.. http://motosynthesis.blogspot.com/p/products.html



Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
Last edited by Jake on Sun Jun 03, 2018 2:53 pm, edited 1 time in total.
Reason: Topic reached 6 pages
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: faffi » Sun Jun 03, 2018 4:14 pm

The CX500, then, if you want to retain a drum brake.

Image

If you want a disc brake, the GL1100 or GL1000 (1100 has the same splines as the CX, the 1000 is different) or the CB900C (same as the GL1100). You also have the Shadow 750 and 1100s where several has shaft drive. Plus the XV535 and XVS650.
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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Wed Jun 06, 2018 4:20 pm

Thank you Faffi, your input as usual is most appreciated.

I have commuted to work a few times now and here are my observations:

Firstly the ducal sport tyres on the 19"/18" combo are not very confidence inspiring.

The front suspension is heaps better with 15 weight oil and 40mm preload spacer added, rebound and damping could still be improved, the Hagen shock on the rear is great I will however play with the damping adjustment to see if it can be made to perform even better.

I swapped back to the original 19"/16" wheels with the Metzeler tyre combo. Much better for fast cornering although the COG shift with the wider tyre lifting the centre line further off the tarmac was a bit weird at first.

The cleaned out spare set of carbs runs better at 1/2-WOT but can be a bit jerky off tick over..

I now have two oil leaks one still from the head gasket on the front cylinder and one from the topmost bolt of the generator cover.. need to do something about that as coming home on Monday the rear wheel felt a bit squirrely and on closer inspection I found the rubber very nicely warmed but the outer edges lightly misted from the engine oil.. not good [emoji15]

So engine out and new gaskets soon..


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: faffi » Wed Jun 06, 2018 4:34 pm

Just learned that the XV535 wheel will take the drive flange from the Gen I wheel, you only need to get rid of a smal ridge in the hub in order to seat the spline coupling fully. Or perhaps you can remove the material from the coupling itself, I don't know. Other than that small operation, it is a bolt-on hub. However, it is offset by about 15-20 mm like that of the Gen II, but I have not been able to verify if that also mean you must unbolt the final drive or not in order to remove/fit the wheel.

At least the 535 wheels should be readily available and much easier to convert than any Honda wheel. The XVS650 wheel should fit with the spline coupling from the Gen II, BTW.

Also, the front wheel off a 535 is only a set of wheel bearings away from being a direct replacement for the front Gen I, even the disc brake is spaced the same. Don't remember for certain if you can use the stock Gen I disc or need that off the 535, but I believe you can use the one from the Gen I.
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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sun Jun 10, 2018 2:13 am

Yes, the XV535 wheel needs to mount the spline flush, for that 5 little ridges need to be got rid off, people have done this with an angle grinder or Dremel or finger sander, neatest results are from a lathe though an I assume the offset can be got rid off when re-spokeing with a 17" rim..

I'll have to measure the gap lathe at work, see if it would fit to machine the splines..

Should I ever get back out of the monetary hole I seem to be in at the moment I'll get a GL1000/1100 rear as it is a 17" already and see what has to be done to convert to Virago splines..

Other than that I have my eye on a wheel building course which would allow me to build properly offset spoked rears for the bikes...


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sun Jun 10, 2018 2:40 am

In other news, I've started on fixing the oil leak. It took about 1-1 1/2hr to get the top off the bike off the engine and take the front head off.

I've cleaned up as best I could the two pistons and cylinders off a spare ' 92 750 parts engine I had to fit back on.

Here's what I found:
Image
Some PO has damaged the tiny bit of material between the camchain gallery O'ring and the outside world by what it looks like attempting to lever the head off with a screwdriver.... no wonder it leaked and it would have done so again.

The head looks ok I think but have little experience in these matters..Image

Unless someone comes forward and tells me something looks wrong I might just leave it alone and swap on the two jugs and pistons from the spare.

Unfortunately I've lent out my cylinder hone and I cannot find my gasket set so everything is on hold till next weekend anyway. Toying with the idea of taking in the jugs and shotblast and repaint as we've the facilities at work to do so..

The '92 (I think it's a '92) came with metal head gaskets which I think must be reusable.. yes?

Here's a pick of the state of the old piston for no other reason than I took one..
Image

And the state the Flying Anvil is in at the moment. Note the two newer jugs and pistons sitting on the floor in the foreground. The rings measure within the spec-ed tolerances in the book so I'll reuse them.Image

More next weekend, I hope.

Cheers,

Rant.



Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: nanno » Sun Jun 10, 2018 3:33 am

Head looks normal, if both inlet and outlet aren't oily on the inside, I wouldn't bother. If you mean by metal gasket the ring, well no strictly speaking it's not reusable. If you mean the MLS (multi-layer-steel) gasket, yes that is.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sun Jun 10, 2018 5:08 pm

Yep, meant the MLS gasket. Neither head looks oily, front one looks a bit lighter/leaner in colour than the rear but that is normal, isn't it?

I have a K&N on the side of the frame, still using original rubber mounts and inserts for the carbs and using stock exhaust (although I removed a heap of what looked like stainless scouring pads from the collector box. The carbs both have 122 main jets..


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: nanno » Mon Jun 11, 2018 12:18 am

Yup, all good.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sat Jun 16, 2018 1:18 pm

I am trying to keep the momentum going so this week the newer jugs and the old heads were shot blast after making various covers and sealing gaskets.

I sprayed the lot in VHT silver stove paint (cheaper than engine paint) then spent an afternoon carefully opening up the various parts very carefully and making sure all traces of grit were removed.

Reassembly required constant rechecking of the manual but both jugs and heads are on now, I took advantage of the frame being off and readjusted the valves.. which were out by what seemed like lots..!?

ImageImageImage

Anyway hopefully I'll get this back together tomorrow..



Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: nanno » Sun Jun 17, 2018 10:01 am

Make sure, you're at the correct TDC (both rockers loose, dot on cam-sprocket pointing up) or otherwise you end up with valves being rather rattly. (Been there done that. :ops: )
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1984 XT500 4Valve (Austrian Tax saving edition)
1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sun Jun 17, 2018 11:59 am

Yup, I can confirm that as of 15mins ago, the Flying Anvil lives again, if a bit rattly.. ;)
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: nanno » Sun Jun 17, 2018 12:04 pm

German proverb: If it still rattles, you haven't lost it. :bg:
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Bike year & model: 1981 Yamaha TR1
1982 Yamaha TR1 Turbo
1977 XS 750 Sidecar
1984 XT500 4Valve (Austrian Tax saving edition)
1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Sun Jun 17, 2018 12:29 pm

nanno wrote:German proverb: If it still rattles, you haven't lost it. :bg:
[emoji23]


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Location: South East UK Flag
Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Fri Jun 22, 2018 2:48 am

The first fire up also highlighted an issue with a previously suspected leaky pet clock, right hand side was a regular fuel fountain straight onto the front cylinder and exhaust![emoji15]

No wonder the oil leak that lived there got wet and runny enough to coat boots swingarm and part of the rear wheel at speed..[emoji32]

Two service kits later.. this bike is still teaching me heaps of new stuff about servicing and mechanics..

I have a vid about it firing back to life but can't seem to find how to get it up in Tapatalk.. I'll post it from somewhere else..


Nothing worth doing is ever easy.

1983 XV750SE CAFE/BRAT - 1981 TR1.1NCENT PROJECT - 1982 XV750/920 upgrade SIDECAR PROJECT w. WATSONIAN MONACO CHAIR
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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rantingsmith
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Posts: 1348
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Joined: Tue Jul 05, 2011 4:24 pm
Location: South East UK Flag
Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: nanno » Fri Jun 22, 2018 9:29 am

If you're capable of punching three holes in a bit of old innertube, you may want to convert to generic Acerbis fuelt petcocks and get rid of the vacuum control at the same time.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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nanno
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Joined: Thu May 26, 2011 4:06 pm
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Bike year & model: 1981 Yamaha TR1
1982 Yamaha TR1 Turbo
1977 XS 750 Sidecar
1984 XT500 4Valve (Austrian Tax saving edition)
1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: Part 2 '82 XV750SE Cafe - The Flying Anvil - a work in p

PostAuthor: rantingsmith » Fri Jun 22, 2018 11:44 am

True but I quite like the automatic petcock function as I would be sure to forget turning it off the day my carbs started leaking fuel into the cylinders and end up with a crankcase full of fuel... ;)
The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Posts: 1348
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Location: South East UK Flag
Bike year & model: 1982 XV750SE UK Model - The Flying Anvil - awaiting better weather

1981 XV920 - sidecar tug project bike - Watsonian Monaco sidecar to be fitted

1981 TR1 - Basket case project - bought completely dismantled and teaching me mechanics 101
Sex: Male



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