My Cafe Racer Build (and Re-Build)

Awesome work on the wheels. What'd you use for anodizing? Was it a kit? Looks like the immersion tray is a wallpaper glue tray? FZR 600 kickstands work well too!
 
Good guess on the wall paper trays! Perfect size for forks. I pretty much used the caswell anodizing method- degrease/rinse/etch(lye)/rinse/desmut/rinse/anodize/rinse/dye/nickel acetate seal.

Used 4 to 1 water/battery acid. Battery charger set to 10 amps for 45 min. Should have yielded around .5 or .6 mils of anodized layer. Dye bath and seal bath were heated using cheap water heater elements made for RVs.
 
And she rolls! Reassembled the RS 125 forks, fresh seals and 20w oil. Going to machine the left and right spacers tonight, then work on the suspension geometry.

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Thanks Chris. Goal is to be done in 2 weeks. Should be doable if I get my shock debacle sorted out. Either all of these suspension companies are busy as hell, or they just really don't give a damn this time of year.

Got the wheel spacers done and the front raised to appropriate height. Since I'm loaded down with caffeine, I may stay up late and start working on the tank, at least get the dents filled and give it a coat of prime.
 
Windscreen holes drilled and mounted. Not too happy with the fit but I made it work. Can't tell if the glass was cut funny or the fairing is off.

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Headlight bucket installed-

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Finally got my head back. Decked, seats done on a serdi, and ports cleaned up. Can't see in the photos, but he did a great job on the area behind the seats in the ports, they were really ugly stock.

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Well I've hit a problem. I have no clearance on the chain to tire. Looks like if I go with a standard 520 chain instead of this RX ring chain, and flip the sprocket backwards and shim the hell out of it, I'll be good to go. Won't know for sure until I pop the motor in.
 
Transmission parts back from REM polishing. I highly recommend getting this done. Our transmission parts are crudely machined, as these bikes were meant to be cheap and used to commute. The REM process did the best job it could to level out all the surface imperfections. And at $60 for all these parts, why not get it done when you have it all out of the motor? The smoothness in the sliding parts is pretty unbelievable, I can only imagine how it will feel once there is oil involved.

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Oooh those transmission bits look schmexy! Since getting mine on the road I've noticed it is stiff to shift. I'd be much obliged to hear where I could send my parts for some finishing. Nice progress too by the way!
 
PEM Racing is the cheapest, since they just toss them in with other customers orders (big parts from cars).
 
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