1980 CB650z RC03 Café Racer (ish) project

[JorgenL]

Assembly time!

Just got the tank parts together and I'm so scared that I'll scratch the paint.
Wet sanded the lock and cap in 3 stages to get them smooth then used a 3M pad to get the brushed look.

The emblem was horrible so I had to bead blast it and re-paint it.

[cb650]

Tank is sweet!!

[VinceInSTL]

I know this thread is older-ish.. but it'd be awesome if you could throw up some finished product pics. Really dig that powder color/paint combo

[Hawk213]

I like your bike man! Very nice! Where'd you get the pod filters? and the exhaust?

[JorgenL]

Got some time left this weekend to put together the last pieces.
Had some problems with a leaking master cylinder but it's all fixed now. The aftermarket (chineese) mastercylinder was not cutting it. It was made for a dual disk setup but was way to soft. Had to use the original MC and modify the new lever to make it fit.
I put a couple of shakedown miles on it, everything good so far.
All that is left now are adjustments and small improvements... and recheck every nut and bolt...

[JorgenL]

I wasn't happy with my muffler so I had to do something about it.
It's originally a Marshall 4-1 system. The muffler is too long for my taste and I needed it to be a bit less restrictive.
I cut the muffler to the desired length, an inch behind the rear axle bolt, made a removable baffle using a small diameter exhaust pipe from a car and perforated it (yes manually in a drill press!!).
I cut a ring that I welded into the opening. This ring has 5 threaded holes that the baffle attaches to with five M5 stainless allen bolts.
For now I'm not packing the system. If needed I will use coarse steel wool (for muffler use).

[pabs11]

I'm loving this bike, especially the front end (handle bar controls, gage, headlight bucket).

I was wondering if you rewired the entire bike, or made modifications to the original wiring harness?

If you've rewired your bike, would you mind sharing your wiring diagram please.


Thank you.