Volcom's Rebuild Build

Well, since every time i try to sit down and make one of these i get booted out of the page and loose 20min worth of work, I'm going to add text after, and let the pictures talk. (They're probably too small, its all i have on my phone ATM)

Bike was top, then bottom after far too long.


3rd ride after finishing. See temp tags

Full engine rebuild to stock specs. Pods, drags with larger slash cut tips and no baffles, Jetted. Passed my friend in his car, said he was doing 110...? Any truth to that? I was filed up with premium and a fresh fuel filter and carb cleaning. On an on ramp hammering out of the hole. Haha

So then i put a lot of hard miles on it, jumped it a few times, some daily riding for a couple months at a time. Never washed it once. Rode in dirt, mud, gravel, torrential downpours to work that left me soaked after 20 seconds or less. Changed the oil religiously, touched points once, cleaned carbs every spring or when i was bored. Occasional condenser, reg/rec or battery lol. But she was good till she pooped on me at Hood Bush in Milwaukee. So i got picked up and then stared at it for a few months and here i am so here's some pics, I've switched a few things up here and there.





A solid machine mostly



Then she started lookin real tired.



So i blew her apart



And then some more



Welded up all the holes and hacked off some useless tabs that are always in my way



Then threw some parts at it. Probably only using few of those. Whats your take on the look?



And that's how it sits right now. At the moment I'm going through my wiring harness and getting rid of the starter so everything will fit in my slim electronics box under my seat.



Plans moving forward are re-lash the valves and 2-1 exhaust, new fender and seat setup, tank mounts... Its on the to do list in one of the pics.

I know I've cried wolf in the past about being back, but I'm back, and hitting it even harder than before. Feels good to be home.

Nvm i cant internet properly.

You said it pooped on you. What broke and how many miles did you get on it before it happened?

never a big fan of the hardtail choppers but i always liked yours.. it looks upper comfortable..

Thanks man. It is really comfortable. Everyone I know (that doesnt ride) rags on it till I make them sit on it.

Chris, it wouldn't hold a charge, couldn't jump it, without it dying in 100 yards or when i wasn't on the throttle. Looking back, and going over my wiring, it appears to be a loose ground, mixed with a short at the starter relay. Also found my brake light switch connectors had pulled out a bit so that explained the bulb flicker. All things I could have fixed but I didnt want to open my PITA electronics box. Figured riding season was over anyway and it needed some things so I got a lift back home. Lazy I know but it was a long weekend lol.

Got the new electronics box tacked up. Much smaller and slimmer than my old one, which was half of a harley FLH oil tank. Waaaay too big for my exhaust plans.

Anderson peg for size and depth reference

Nice, very tidy.

levdir said:

Nice, very tidy.

Click to expand...

Thanks man, that's my aim this time around.

Bought a mikesxs exhaust builder kit and a pamco ignition. Both are things I've been drooling over for this bike. Any guesses as to exhaust plans? Hahaha
A teaser.

Tire heater... good idea

LuckyEight said:

Tire heater... good idea

Click to expand...

Bum burner more like

Haha easy guys, its a mock up lol

Damn Volcom, back at it again with the flakeyness. Sorry for the lack if updates. Various reasons abound, but most are excuses, so ill just hop to it with progress pics.

I had picked up a front end off some Kawasucki for $25 with knob-adjustable fork dive dampers that activate when your front brake switch gets signal. So i wanted to hook that up to an on/off switch and fiddle with it based on road conditions, or if i was riding in the dirt etc...

I thought it looked tough.


But it proved to be too much work, as i was searchin in yamahas parts bin for a longer, thicker front end. As i was adding things to my ebay cart a line was dropped that that very front end was for sale. So i scooped it up. And it was everything i had hoped for and more.

It's looking good there! Needs more pics of progress!

So that came courtesy of mototrooper.
Correct me if im wrong, but the front end consists of:
TT500 trees.
Virago 535 forks and lowers.
Machined XS400 front axle.
SR500 rotor.
Fzr600-900 front caliper.
Renthal bars.
Fancy TDM870 adjustable master cylinder.
And a fender that is JUST too small to fit my tire.

Then she looked like this

The triple trees are TT500 ones (the dirt-track racer model of the SR500), the forks are 36mm Virago 535's, the brake master is a TDM850, and the rest you know. Glad to see it's going to a cool build! Didn't want to pressure you but was anxious to see how it would look. Finish it soon!

Then i needed a New electronics box, as my previous design was juuuust too shallow to fit my key switch.






Did that, got it mounted up, and moved onto the pegs. My old setup was some,large bolts running thru my frame where the bolts stuck out for the frame for the stock pegs. I cut those off, drilled it out and ran bolts thru. Well that doesnt really work well, as the holes got wallowed out pretty bad.

So i turned some slugs on the lathe. (tall ones on the right)


Welded em in


Mounted some cherry/posa knock-offs.


With that sorted I moved to the tank. Same thing as pegs, thru hole wallowed out, so i tossed some tubing in it and welded it up.


Then coil mounts. They always break or crack off. Like 2 times a season. This is the 3rd time ive remade mounts for it, and the 3rd style I've tried. Hopefully this works.

For the coil mounts why not tie them into the backbone as well? Looks like just a little bigger piece of sheet metal that reaches to the backbone would work. That should keep them from breaking. Unless I'm not looking at it right.