2003 XL883 to Ryca Motors Cafe project

Discussion in 'Some Assembly Required' started by 1stiski, Dec 3, 2013.

  1. 1stiski

    1stiski Ride that nasty thing

    Joined:
    Oct 23, 2003
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    1,673
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    Elizabethville, PA
    Had the Cafe bike dream hanging in my brain for quite a few years now , and while doing some recent research and an offer on a low mileage old 76 Suzuki 360 really put this into motion. The Suzuki deal has been hanging in the shadows for a few months, and the seller just can't commit. So enough is enough, the search really took hold once i saw a Utube short on Ryca Motors and Jay Leno reviewing their Suzuki S40 conversion (www.rycamotors.com) . The search for a donor started. The Suzuki was nice but once I scrolled to the Sportster offer, I was sold on going the Harley Davidson route. SO I began the search. I was able to snap up this very clean 2003 (Ryca has a kit ava for 91-03) with low mileage and the right price (winter prices).

    [​IMG]

    [​IMG]

    Seems to be a shame to tear it apart, but thats life. day one.



    Those long frame rails will be getting cut off and shaved for fitment of mini LED tail signals. The wire loom will need to be shortened in the process.
    [​IMG]

    The slash cut pipes come off next
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    Ordered my Kit and should have that in the next two weeks. I'll have plenty to do meantime.
    #1
  2. dgrs2

    dgrs2 Where'd I leave my knee??

    Joined:
    Oct 14, 2003
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    Jim Thorpe, PA
    Great project bro. I'll be watching!
    #2
  3. verdelac

    verdelac Rust never sleeps

    Joined:
    Sep 18, 2013
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    289
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    Cleveland
    I'm in! Thanks.

    You can probably sell that 100 anniversary paint set for some decent change.
    #3
  4. Wyocrawler

    Wyocrawler Been here awhile

    Joined:
    Oct 25, 2013
    Oddometer:
    116
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    Marietta ohio
    Really can't wait to see how this turns out!
    #4
  5. Brian Keith

    Brian Keith Been here awhile

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    Sep 17, 2013
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    194
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    Colorado Springs, Colorado
    I just subscribed, I'm looking forward to the build and end result.
    #5
  6. TimCC

    TimCC Been here awhile

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    Aug 4, 2011
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    403
    Location:
    Madison, WI
    Very cool. I can't wait to see the process. I really like the underbody exhaust they have on their site.
    #6
  7. DesmoDog

    DesmoDog Desmo's my dog

    Joined:
    Jun 25, 2009
    Oddometer:
    740
    Location:
    Michigan, USA
    I'll be interested to see how this goes. One of the few bikes left on my list of possible projects is a Sportster powered "cafe racer". :lurk
    #7
  8. Kennon

    Kennon Been here awhile

    Joined:
    Aug 25, 2011
    Oddometer:
    323
    Location:
    Oxford, NT Hong Kong, Moscow
    keeping a eye on this build
    #8
  9. markjenn

    markjenn Long timer

    Joined:
    Nov 9, 2003
    Oddometer:
    10,482
    Location:
    Swellvue, WA
    I've been interested in these Ryca kits - keep up the good work and take a lot of pictures.

    - Mark
    #9
  10. adventurebound9517

    adventurebound9517 Been here awhile

    Joined:
    Mar 28, 2011
    Oddometer:
    342
    Location:
    Lake Havasu City, AZ.
    I'm in for the build. :clap
    #10
  11. verdelac

    verdelac Rust never sleeps

    Joined:
    Sep 18, 2013
    Oddometer:
    289
    Location:
    Cleveland
    Ive got an old Norton Commando that I tried to sell. Too many missing parts for a restoration. But I was able to hang an R1 front end on it and I'm looking for a donor sporty for the drive.

    Real interested in whats going on here.
    #11
  12. yokesman

    yokesman Been here awhile

    Joined:
    Sep 12, 2008
    Oddometer:
    550
    Verde
    that would be a trick,to put a HD box behind the Norton engine,you have a 5-6 spd,or 4 and NEVER brake it.
    had a 850 commando,3x thru the box in 33kmiles.
    #12
  13. 1stiski

    1stiski Ride that nasty thing

    Joined:
    Oct 23, 2003
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    Location:
    Elizabethville, PA
    ordered up some parts today. I've got the Oberon LED turn signals on order, custom made cnc'd black anodized , unique product, I like the fact that the LED's light both front and back for more safety along with high output for visibility, no lame dim LED's for me.
    http://www.oberon-performance.com/acatalog/Oberon_Mini_LED_Motorcycle_Indicators.html

    for front duty mounting, going with the GSG cnc'd black anodized turn signal mounts
    http://www.streetfightersinc.com/images/GSGTurnSignalBracketCNC.jpg

    I have a 5 week wait on those parts due to the custom manufacturing from Jolly old England
    #13
  14. 1stiski

    1stiski Ride that nasty thing

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    #14
  15. msmetz

    msmetz Been here awhile

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    Any plans to change the wheels?
    #15
  16. 1stiski

    1stiski Ride that nasty thing

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    #16
  17. verdelac

    verdelac Rust never sleeps

    Joined:
    Sep 18, 2013
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    Location:
    Cleveland
    Those wheels are nice. Pricey?
    #17
  18. 1stiski

    1stiski Ride that nasty thing

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    Yes , pricy . :eek1
    #18
  19. 1stiski

    1stiski Ride that nasty thing

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    Today,
    Took off the pipes, and removed the rear brake master cylinder, along with the foot brake and hardware. The master cylinder will be switched around for the rear sets. Up front I removed the front wheel and the fender. The safety reflectors came off, and the front brake caliper removed. I wanted to prep the lowers for paint (going with a satin black finish) and I wanted to see the upper rubber wipes , so I moved the caps off. All looks well underneath, and no scuffs. I think the wipes can stay.
    [​IMG]



    all looks well in the final drive area, no tell tail leaks
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    Forks, checking the wipes/ seals. All looks good, some surface prep, with etching primer will be in order then the satin black.
    [​IMG]


    Enough for today.
    [​IMG]
    #19
  20. 1stiski

    1stiski Ride that nasty thing

    Joined:
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    Todays rainy day project was to prep the forks. First a nice 320 grit sand, solvent cleaning, tape up the mounting holes for the axle and brake caliper, then 4 coats of etching primer, wait 2 hours and 7 light coats of Satin Black. IT came out perfect. I'm satisfied.

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    After looking for new wheels, and the price involved in purchase, I thought I can resurrect the stock wheels, but primp them a bit... Took off the tire, and started off with a good aluminum polish to see if the rim and slight oxidation will come off. Success was had , so I'm going chemical clean the rest of spokes of the wheel , then tape off the polished lip and primer etch the rest , along with satin black for the rest of the wheel. My guess is they will come out pretty nice, especially since they are in relatively good shape

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    I'll be tackling that tomorrow . First the front, then the rear.

    The contrast between the satin black and polished lip should make for a nice wheel combo. Plus I can save almost $2500 in the process.
    #20