'75 S1 Cafe racer project. - Chicagoland Sportbikes
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post #1 of 61 (permalink) Old 02-20-2009, 09:28 AM Thread Starter
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'75 S1 Cafe racer project. UPDATE!!!

Hi there. This is a little teaser of a cafe racer I got in works right now.
This project started with a 1975 S1 250 triple rolling cage I got late last summer.
I love the look of it and the three exhaust pipes are just to damn sexy. I was originally going to fit it with a original motor and restore it to it's previous glory.
But finding parts for it proved a little to hard. And a thought of an old two stroke with outdated brakes and suspension in this city was a scary proposition. Especially since I really wanna use it as a daily rider.
So idea arose of fitting it with a more reliable water cooled motor and modern suspension. And that's when a '02 EX250 was introduced to the mix.
Now I know I'm pissing some true old timers off by swaying away from original and this bike is never gonna be true to the cafe racer legacy. So as a consolation and apology I'll try to keep the looks as close as possible to some of the London's Ace club models I'w seen in pics.

Color is sill to be decided on as is the fuel tank shape, but I got some ideas I'm leaning towards.
So any suggestions and tips and help is welcome. Also feel free to help your self to any of the old bike parts if you need them.
I'll keep you posted as the progress is being made.
Thanks for letting me share this with you.
Attached Images
File Type: jpg Lucy.jpg (54.7 KB, 92 views)
File Type: jpg Lucy being striped down.jpg (63.6 KB, 84 views)
File Type: jpg EX2507.jpg (75.8 KB, 125 views)
File Type: jpg doner being striped down.jpg (69.3 KB, 82 views)
File Type: jpg waiting for transplant.jpg (61.3 KB, 79 views)

Last edited by r1srb; 02-25-2009 at 12:25 PM.
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post #2 of 61 (permalink) Old 02-20-2009, 12:35 PM
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cool!

Chris
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post #3 of 61 (permalink) Old 02-20-2009, 01:00 PM
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oh snap... i gotta get over there tonight dont want to be hold this up any.

ill hopefully be sneaking out early today to get over there before 5

-Jason
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post #4 of 61 (permalink) Old 02-20-2009, 02:00 PM
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That's hella cool!

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post #5 of 61 (permalink) Old 02-21-2009, 10:20 PM
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Ive got the 75 frame, 02 motor and am working to marry the two happily

just getting the motor in the cradle took some fanagling but its in and the lower rear mount is thru bolted and at least giving me engine alignment to the frame, need to get the rear wheel and rear shock so i can get a side to side alignment for the sprockets. need to figure out the rear shock mounting as well, trying to keep the 02 geometry intact as much as possible in the process.

Ill post mock up pics shortly

-Jason
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post #6 of 61 (permalink) Old 02-21-2009, 10:31 PM

 
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Makes me sweat.

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post #7 of 61 (permalink) Old 02-21-2009, 10:31 PM
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Nice!

Take it to the STREETS!
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post #8 of 61 (permalink) Old 02-21-2009, 11:28 PM
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Quote:
Originally Posted by resurrection View Post
Makes me sweat.
in a good way i hope

-Jason
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post #9 of 61 (permalink) Old 02-21-2009, 11:54 PM

 
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My brain starts working on my next project when I see others and theirs. Thing is that thaught puts me 4 projects behind EVERY TIME.

Good luck with yours. It's important to keep your head of steam and team work helps.

One of the troubles I've had is trying to find that perfect part .If you let that one part slow down the build it may loose momentum and that sucks.

Go with the flow and what comes your way and next thing ya now your sweating while kickstarting the bike.

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post #10 of 61 (permalink) Old 02-22-2009, 12:14 AM
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ive got the easy part
fab and welding

a little teaser

-Jason
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post #11 of 61 (permalink) Old 02-22-2009, 09:06 AM
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Nice project. Kickstart FTW. I pick up my project bike next week.
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post #12 of 61 (permalink) Old 02-22-2009, 09:15 AM
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kickstart.... 02 ex250 doesnt have one

-Jason
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post #13 of 61 (permalink) Old 02-22-2009, 09:31 AM
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Kickstart fail.
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post #14 of 61 (permalink) Old 02-22-2009, 10:27 AM Thread Starter
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AND NOW THE FUN PART:
I'm playing with the front suspension set up right now.
As you can see the triples look a little different and I wanna use the one of the newer model.
New tubes and triple clamps are wider and stem going trough the headstock is about half an inch too long. Now I toyed with the idea of putting spacers but I don't see that working.
Bearings are the same and the width of the steam seems the same on the machined surface. So is the tread used to secure it.
Now cutting it shorter and retreading it won't work cause it's not even machined surface but rather thinner un machined cast.
I'm out of ideas at this point so any help would be appreciated.
Thanks.
Attached Images
File Type: jpg both tt bottom.jpg (40.4 KB, 8 views)
File Type: jpg both tt top.jpg (42.3 KB, 8 views)

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post #15 of 61 (permalink) Old 02-25-2009, 12:34 PM Thread Starter
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What no tips or suggestions. Am I gonna have to put a pic of a monkey spanking it to get some attention here.
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post #16 of 61 (permalink) Old 03-01-2009, 11:19 PM

 
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More monkeys Here.


So far so good I've machined out the weld on both lower clamps and pressed the stems out .I will need a spacer 28mm ID and 30mm OD for pressing the old stem into the new lower clamp then we will weld in place .

The complete late model frontend will bolt right on the old frame






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I'd love to help but I don't chase parts.
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Last edited by resurrection; 03-01-2009 at 11:22 PM.
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post #17 of 61 (permalink) Old 03-01-2009, 11:55 PM
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One nice thing about Resurrection. He does the work you ask him to do in a timely manor. That part was dropped off yesterday, and Gus is working hard at it. And its not because Gus is slow.
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post #18 of 61 (permalink) Old 03-02-2009, 12:09 AM
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Also very cool to meet you. Looks like you are making a lot of progress. Are you doing anything with the origional engine? (Dave13 looking as sheepish as possible)
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post #19 of 61 (permalink) Old 03-02-2009, 10:15 AM Thread Starter
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Thanks Gus, looks awesome. You truly exceeded my expectations. I'm so glad I met you and will be bringing all my fab needs to you. As well as spreading the gospel of Team Resurrection. I saw your work and can honestly say that you do a great job. Also to say that you are moderately priced would be an understatement.
This is a truly nice bunch of guys.
BTW Pleasure meeting Dave13 as well. Hope to see you all again soon.
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post #20 of 61 (permalink) Old 03-02-2009, 11:29 AM
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wow... looks like im holding things up. Ill be getting the swing arm inner pivot tube ground to length today, from there I can fit the swingarm in the frame minus the pivot bearing seals(temporarily) Ill get the swing arm side spacing set tonight and have material removed from its width tomorrow. then its on to finishing up engine mount points, making mount spacers to hold side to side location on the lower rear mount, and finally reworking the top tube area near the steering neck to accomodate the engine and its waterneck

-Jason
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post #21 of 61 (permalink) Old 03-02-2009, 12:53 PM Thread Starter
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No hold up my man. Hope you're feeling better. Still plenty of time before riding season. Judging by the weather today we might have till mid August.
How's that rear shock placement coming along. Is it giving you hard time?
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post #22 of 61 (permalink) Old 03-02-2009, 12:56 PM
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I havent gotten that far yet, gotta get the motor and swingarm settled first

-Jason
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post #23 of 61 (permalink) Old 03-02-2009, 06:57 PM

 
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sorry don't mean to pressure anybody .But dammit lets get the show on the road

We still have some foot peg mounting issues.I'm thinking maybe some bolt on offset rear sets,and maybe some radiator mounts.

Gus
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I'd love to help but I don't chase parts.
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post #24 of 61 (permalink) Old 03-02-2009, 08:20 PM
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Gus I'm hanging this Friday, keep the heat on and the beer cold!


Too bad I missed out on meeting a few more from CLSB, but I'm sure there will be a next time.

-Jim
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post #25 of 61 (permalink) Old 03-02-2009, 08:47 PM

 
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Friday then

Gus
We offer three kinds of service @ Resurrection
GOOD - CHEAP - FAST
You can pick any two
GOOD service CHEAP won't be FAST
GOOD service FAST won't be CHEAP
FAST service CHEAP won't be GOOD
and cold beer.

I'd love to help but I don't chase parts.
Please contact other forum members and supporters for parts.

Last edited by resurrection; 03-03-2009 at 12:17 AM.
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post #26 of 61 (permalink) Old 03-02-2009, 10:13 PM
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Swingarm placement is settled I need to remove about .050 to allow free enough movement and not crush the seal ends.

The original ex250 chain i found out is too short, it will need probably 10 links added

I also got the upper water neck clearance figured out I think, Im leaving as much original steel uncut as possible to help maintain strength and the original frame geometry.I will be plating the front cross tube where I had to cut the top tube to make sure its strong enough.

-Jason
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post #27 of 61 (permalink) Old 03-03-2009, 12:20 AM

 
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Will the swing arm bushings need to go inbound ?

Is there a spacer between them?

Gus
We offer three kinds of service @ Resurrection
GOOD - CHEAP - FAST
You can pick any two
GOOD service CHEAP won't be FAST
GOOD service FAST won't be CHEAP
FAST service CHEAP won't be GOOD
and cold beer.

I'd love to help but I don't chase parts.
Please contact other forum members and supporters for parts.
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post #28 of 61 (permalink) Old 03-03-2009, 06:26 AM
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there are no swing arm bushings, the swing arm rides on a pivot tube, a bolt passes thru the tube to the frame halves. the pivot tube is supported by 2 caged needle roller bearings, one per side. they may need to be pressed in a few thousandths further to accomodate the swing arm being made narrower and allow the seals to seat fully. Ill measure everythind again to confirm before anything gets ground off

-Jason
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post #29 of 61 (permalink) Old 03-03-2009, 06:40 AM

 
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Bushings ,bearings What ever you got my drift.
My concern was a shoulder in the arm for bearing stop

Gus
We offer three kinds of service @ Resurrection
GOOD - CHEAP - FAST
You can pick any two
GOOD service CHEAP won't be FAST
GOOD service FAST won't be CHEAP
FAST service CHEAP won't be GOOD
and cold beer.

I'd love to help but I don't chase parts.
Please contact other forum members and supporters for parts.
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post #30 of 61 (permalink) Old 03-03-2009, 06:49 AM
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Ill be x-raying the swing arm to see if there is a stop in there today , Ive looked and dont see one but its dark even with a light and if i dont have to punch the bearings out then so much the better

-Jason
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