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The "poor judgment" cafe project: '83 xv920

Chop it, rake it, slam it, build it for show.
New parts, old parts, built from scrap. [Hammered out of bare stock & welded with sweat.]
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Fri Sep 07, 2018 5:48 am

Below is the ROUGH DRAFT of the wiring I'll be doing on my bike. Please be aware that it is a DRAFT, so please don't download and take off running to the garage.

I would like everyone to look at it and comment where necessary. Please let me know if you see something that's off, or wrong, or could be done better.

NOTE: the wiring in this diagram is spread out in a grid-like manner to show the connections clearly. The actual wiring will be much more streamlined, and will not have zillions of tie-ins, as shown on the current diagram.

draftwiring.jpg
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Thu Sep 13, 2018 3:53 pm

What do I need to do to get Dan to come to this thread and check out the wiring diagram? Does anyone know how to reach him? Not answering PM or regular email.

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: spectra » Wed Sep 26, 2018 9:00 pm

How goes the build?

Figure out the wiring?

Just put in a order with Cognito my build will start this winter for sure now...........

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sun Sep 30, 2018 6:27 am

The build has been going slow as heck- not to my liking but I've had little time lately.

And the entire left side was held up by the missing O-ring that goes between the push rod and the adjusting screw, costs all of $1 but took forever to ship. Finally got it the other day:

Oring.JPG


Used the grease trick to affix it to the inward tip of the adjusting screw, as well as holding the ball retainer plate (triangle with bearings) and push screw in place while installing the stator cover which went in after a bit of jiggling and a lot of swearing.

Then I lubed and then hooked up a new motion pro clutch cable after setting the adjusting screw (screwing all the way in, clockwise, until contact, then backing out 1/4 turn) and putting push lever assembly together.

clutch.JPG


Andddddd all done:

statcover.jpg


Hooked up the cable to the clutch lever and it works smoothly, even without oil in the crankcase.
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sun Sep 30, 2018 6:35 am

Next up: the headlight. I have to figure out a way to fab a plate to mount it on. More on that soon.

Just got word the tank is done and will be shipped to me soon.
Carbs are just about done as well.

Next up will be reinstalling rear brake. I've taken off the passenger pegs brackets to remove the anodizing and polish them.

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sun Sep 30, 2018 5:59 pm

Here's the headlight setup that I"m thinking of getting fabbed- maybe a 7/8" x 7/8" square tubing of stainless steel welded to a plate mounting to underneath the bottom TT clamp..? (See the two screws that protrude from underneath the bottom clamp.)

Wonder if 2-3" square tubing would make the setup look silly, or amateurish?

headlight.jpg
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: spectra » Sun Oct 07, 2018 5:57 pm

Looking good! as for the headlight not sure on the tube.......how does everyone else do it on these?

Also whats in the background? I see a brat style frame and shocks........... :bg:

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: briandk » Mon Oct 08, 2018 2:17 am

What software are you using to do your wire diagram? It looks so nice and clean :)

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Mon Oct 08, 2018 11:25 am

spectra wrote:Looking good! as for the headlight not sure on the tube.......how does everyone else do it on these?

Also whats in the background? I see a brat style frame and shocks........... :bg:


I think I've found a solution for the headlight, found a bates style mount on the cognito moto website. It'll be here tomorrow.

In the background- that's my BMW scramber project. It's up next, after I finish the Virago.

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Mon Oct 08, 2018 11:26 am

briandk wrote:What software are you using to do your wire diagram? It looks so nice and clean :)


Thanks- it's photoshop.

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Mon Oct 08, 2018 11:27 am

I'm in the process of putting the rear brake back on, and just realized that with the battery housing gone, I will not be able to hook up the rear brake light switch the conventional way.

I'd like to ask those of you who cafe'd your viragos how you dealt with this problem. Pictures and/or advices would be great!

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Mon Oct 08, 2018 11:59 am

This guy had a good solution:

viewtopic.php?f=61&t=52343

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Thu Oct 11, 2018 3:56 pm

The bates headlight mount from Cognito Moto turned out to be a lifesaver. I drilled and tapped mounting holes on the lower TT clamp, and it went on perfect.

HL.jpg


mount.jpg
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: spectra » Fri Oct 12, 2018 8:52 pm

Looks nice but you couldnt make that ?

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sat Oct 13, 2018 2:28 pm

spectra wrote:Looks nice but you couldnt make that ?


No. I wish I had the tools and the space to fabricate stuff. Someday...

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sat Oct 13, 2018 2:29 pm

Found some time today to put in the air filter.

Next up is ordering the R/R and installing it behind the left side passenger peg bracket. Also get the new coils, plugs, wires.

airfilter.JPG
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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: spectra » Sat Oct 13, 2018 8:02 pm

Looks good! What RR are you going with ? Aftermarket coils or factory ? Hell the 920 is new to me so not even sure whats out there for them aftermarket wise......

I just picked up a lift so may just have to start dis assembly soon.........

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sat Oct 13, 2018 8:18 pm

spectra wrote:Looks good! What RR are you going with ? Aftermarket coils or factory ? Hell the 920 is new to me so not even sure whats out there for them aftermarket wise......

I just picked up a lift so may just have to start dis assembly soon.........


Since I am going with a lithium ion battery tucked under the gas tank, I need to get a R/R compatible with that. Going with the one from Rick's:

https://ricksmotorsportelectrics.com/Li ... tor-14_409

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: spectra » Sat Oct 13, 2018 10:39 pm

Ah ok I have one of those on a 400 I did with a antigravity battery..............also purchased a 12 cell for the Virago so let me add that tot he list of more things I need..............

Thanks!

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Re: The "poor judgment" cafe project: '83 xv920

PostAuthor: wrenchguy » Sun Oct 14, 2018 6:25 am

spectra wrote:Ah ok I have one of those on a 400 I did with a antigravity battery..............also purchased a 12 cell for the Virago so let me add that tot he list of more things I need..............

Thanks!


Mine is only an 8 cell anti-gravity. Hope that will be enough. I am going to attach a charger port to it just to be safe.

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