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Old 12-22-2009, 06:51 PM   #1
rkatapt OP
Indo-Kraut
 
Joined: Jun 2008
Location: Dallas, TX
Oddometer: 261
Lets Do This....Airhead Cafe

So I can say this is the first time for me doing something like this on a motorcycle and it is also my first airhead. I will more than likely have a lot of questions for you ever knowledgeable airheaded people here.
I've seen a lot of inspirational threads on this site and I've been thinking about doing this for the last two years. So the people of ADV please o' please don't let me turn this into a basket case.

On the block 1975 R90/6 mileage is exempt and I got it for a heck of a price.
When I got it, this picture makes it look much nicer I swear quite nice actually. Crappy camera or really good camera the picture lies.


Slowly went to this....



Time to build this thing from the ground up, shall we start?

Took the tank off and its pretty dented and dinged up from the previous owner.
Local shop told me $100 cash to fix the dents and dings no paint. Does this sound like a good deal?



Inside tank it's not actually rust but a rust colored coating that is flaking off everywhere.


No tank or seat and lots of rust....


Broke a rubber standoff on the battery box. It's ok though I am mounting the battery elsehwere.


The other side more rust....


Leaky master cylinder


Look at all that corrosion on the lower beam, (why would it be so corroded?)


Glad its got a Dyna III, I want to relocate this thing.


Looks like petcock rebuild time as well.


Not sure what this thing is, but the mount is broken.


Other side showing more corrosion...the blue tape is my method of marking what all the wire leads go to.


This is how I left it I need a bigger wrench to get the ignition side headlight bucket nut off. I will grab one from work. Atleast most of the wiring is pulled through and labeled.


Lots of wrenching ahead of me and that's it for now. I won't be able to get back to it until probably this weekend due to xmas and all. I have so many plans for this thing that it keeps me up at night thinking about it. I keep thinking oh please god let me be able to put this thing back together again.

rkatapt screwed with this post 03-15-2010 at 07:55 AM
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Old 12-22-2009, 06:55 PM   #2
BrianK
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"Look at all that corrosion on the lower beam, (why would it be so corroded?)"

Leaky master cylinder, corrosive brake fluid drips down and wind and inertia push it back along the tubes....
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Old 12-22-2009, 06:59 PM   #3
rkatapt OP
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Location: Dallas, TX
Oddometer: 261
Quote:
Originally Posted by BrianK
Leaky master cylinder, corrosive brake fluid drips down and wind and inertia push it back along the tubes....
It's what I thought but, why not the top crosstube?
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Old 12-22-2009, 07:18 PM   #4
Cogswell
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Be sure to take lots of pictures as you disassemble. Label baggies to put parts and fasteners in.

We will be cheering you on.


Mike
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Old 12-23-2009, 03:20 AM   #5
SamH
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Hah, your bike has almost identical wear and rust to mine. I guess it's pretty typical of the bike, leaky master cylinders are easy to miss being under the tank. The battery box is the same. Those ingenious little dimples around the three bolts at the bottom. Perfect for catching water or, worst case scenario, battery acid.

Can't wait to see the rest. And hear it for that matter, those are some brutal looking megaphones. Oh, and speaking of brutal... the seat?

SamH screwed with this post 12-23-2009 at 03:32 AM
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Old 12-23-2009, 04:23 AM   #6
norton73
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Broken piece is the voltage regulator, probably another victim of the leaky M/C. Replace it with a solid state one from Motoradd Electric or Euro Motoelectrics while you're there.
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Old 12-23-2009, 04:29 AM   #7
rkatapt OP
Indo-Kraut
 
Joined: Jun 2008
Location: Dallas, TX
Oddometer: 261
Quote:
Originally Posted by Cogswell
Be sure to take lots of pictures as you disassemble. Label baggies to put parts and fasteners in.

We will be cheering you on.


Mike
I've got a bunch of baggies and tape for the id process. I am also bldg a computer just for the garage so when the time comes I can view photos while assembling this thing. Thanks for the cheers!

Quote:
Originally Posted by SamH
Hah, your bike has almost identical wear and rust to mine. I guess it's pretty typical of the bike, leaky master cylinders are easy to miss being under the tank. The battery box is the same. Those ingenious little dimples around the three bolts at the bottom. Perfect for catching water or, worst case scenario, battery acid.

Can't wait to see the rest. And hear it for that matter, those are some brutal looking megaphones. Oh, and speaking of brutal... the seat?
I am thinking a handlbar mounted master cylinder and I want to move the battery under the rear fairing (haven't gotten it yet). So I do nto know how it will fit.

I have a video of it running with that exhaust on. That was my free method of spicing up the exhaust. The original was scarred to hell from the previous owner making pretty yellow sparks on the pavement. That exhaust still has one baffle inside of it so it's not open. It is louder than stock and I will be applying another baffle at the exit to kill the "megaphone effect".

Quote:
Originally Posted by norton73
Broken piece is the voltage regulator, probably another victim of the leaky M/C. Replace it with a solid state one from Motoradd Electric or Euro Motoelectrics while you're there.
Note taken thanks!
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Old 12-23-2009, 04:30 AM   #8
rkatapt OP
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oops dp delete....
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Old 12-24-2009, 09:53 AM   #9
rkatapt OP
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Location: Dallas, TX
Oddometer: 261
Quote:
Originally Posted by SamH
Can't wait to see the rest. And hear it for that matter, those are some brutal looking megaphones. Oh, and speaking of brutal...
Video of it starting with that exhaust...a bit loud going to make another baffle at the end to shut it up.

R90/6 Single Baffle from Ronnie Stag on Vimeo.



Also, sounds like I need to do some carb work.

rkatapt screwed with this post 12-28-2009 at 06:07 PM
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Old 12-25-2009, 07:57 PM   #10
travelpix
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master cylinder

Saw a cable actuated , remotely mounted master cylinder on a bike once. Handlebar hydraulic cylinders are ugly.
Just a thought.
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Old 12-25-2009, 09:00 PM   #11
crazydrummerdude
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You gotta do something with that fugly seat..

Otherwise,
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Old 12-26-2009, 06:08 AM   #12
rkatapt OP
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Joined: Jun 2008
Location: Dallas, TX
Oddometer: 261
Quote:
Originally Posted by crazydrummerdude
You gotta do something with that fugly seat..

Otherwise,
No fear I just bought a tailpiece.

Jonesin' to get in the garage and work on it.
(shakes stick at family in town)

rkatapt screwed with this post 12-26-2009 at 07:32 AM
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Old 12-26-2009, 07:26 AM   #13
alixsidecarbmw
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Cafe resto project

Another good source, if not already mentioned, is the "Do the ton" site. Great info on every aspect of the Cafe scene and restoration world. I have been relying heavily on both sites lately.

Scott
1976 GS750 Cafe project
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Old 01-03-2010, 06:32 PM   #14
rkatapt OP
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Joined: Jun 2008
Location: Dallas, TX
Oddometer: 261
Quote:
Originally Posted by alixsidecarbmw
Another good source, if not already mentioned, is the "Do the ton" site. Great info on every aspect of the Cafe scene and restoration world. I have been relying heavily on both sites lately.

Scott
1976 GS750 Cafe project
Signed up over at www.dotheton.com under the same name.

I am most definitely constructing rearsets the same way sparkymoto and Herm21 did. Already have parts picked out.

Speaking of parts I got some new stuff in. I haven't had much time to continue with the teardown due to the holidays, family, and traveling.

New stuff: shocks, clip-ons, fork gaiters, UNI Air Filters, black exhaust wrap, seat pan, and tail piece.


As she sits long way to go for the tear down. Not much more done since the last update.

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Old 01-03-2010, 07:22 PM   #15
sparkymoto
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Moving along nicely!
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