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 Post subject: ryca build project
 Post Posted: Sun Feb 27, 2011 4:43 am 
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Hornet Warrior
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Location: Ogden, Illinois, USA
I have started the Ryca CS-1 cafe racer project as presented in Cycle World a few months back (http://www.rycamotors.com). You start with a 650 Suzuki Savage single cylinder cruiser and end up with a cool cafe racer. I have secured the donor bike and ordered the kit. My chief assistant and I have started the tear down. I will update the progress of the project in this thread.

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Last edited by bikertrash on Sun Feb 27, 2011 4:46 am, edited 1 time in total.

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:45 am 
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Hornet Warrior
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What we started with:
[RSimg]Image[/RSimg]

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:47 am 
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Hornet Warrior
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Removing the seat:
[RSimg]Image[/RSimg]

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:49 am 
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Hornet Warrior
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Removing the side covers:
[RSimg]Image[/RSimg]

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:50 am 
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Hornet Warrior
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Preparing to remove the rear fender:
[RSimg]Image[/RSimg]

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:51 am 
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Hornet Warrior
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Rear wheel, rear fender, and some other bits removed:
[RSimg]Image[/RSimg]

Stay tooned! :D

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 11:28 am 
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Wannaprilia
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nice one. looks like your lad is doing all the work :rollin .

one i've seen makes me want a savage as a hack...
Image
Image

check out the rear brake setup.
disc on the front sprocket to keep the rear end clean.mmmmm. bobber.

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 11:28 am 
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Hornet Warrior
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Awesome project, can't wait to see it finished, had no idea that an old suzuki savage has potential :ahhdiddums

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 4:38 pm 
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Hornet Warrior
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Nice one :thumbup
Your chief assistant looks like a handy fella to have around :D

Good clean donor bike, keep the pics coming :)


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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 6:21 pm 
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Jesus ! Get a life !
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Nice to see Dads letting their sons do stuff like that! Could be the start of a lifelong interest for him :D

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 9:17 pm 
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Hornet Warrior
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joey23 wrote:
Nice one :thumbup
Your chief assistant looks like a handy fella to have around :D

He is an aspiring hooligan--he has an older brother who did not inherit the biker gene :(

Good clean donor bike, keep the pics coming :)


I paid $700 for that bike, so I don't feel to bad tearing into it :angel

I will definitely keep the pics coming--trouble is, my vocation gets in the way of my avocation and only get to work on it once a week :Bang

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 Post subject: Re: ryca build project
 Post Posted: Sun Feb 27, 2011 9:18 pm 
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Hornet Warrior
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Rich M wrote:
Nice to see Dads letting their sons do stuff like that! Could be the start of a lifelong interest for him :D


I told my missus that I should be nominated for father of the year :angel

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 Post subject: Re: ryca build project
 Post Posted: Sat Mar 05, 2011 10:32 am 
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Hornet Lord

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a friend of mine bought a we 50cc bike for his sons 10th birthday it happened to be in kit set form including all the engine bits they had a great time putting it together and the joy on their faces when it turned over for the first time was amazing


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 Post subject: Re: ryca build project
 Post Posted: Sun Mar 06, 2011 4:58 am 
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Hornet Warrior
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We are a long way from the first test drive, but plan on tearing more parts off tomorrow--I'll try to get some more pics posted up soon . . .

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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 08, 2011 8:48 pm 
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Hornet Warrior
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OK, here are the results of another afternoon of dismantling:

Battery box removal
[RSimg]Image[/RSimg]

Battery box removed
[RSimg]Image[/RSimg]

Tank removed
[RSimg]Image[/RSimg]

Carb removal
[RSimg]Image[/RSimg]

Airbox removal
[RSimg]Image[/RSimg]

The progress thus far
[RSimg]Image[/RSimg]

Stay tuned! :D

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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 08, 2011 9:04 pm 
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Hornet Warrior
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:clap

Keep the pics coming.

Funny how the more parts you take off the bike the better it looks :lol
Sorry hate cruisers :angel
But soon, its goin to look :love


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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 14, 2011 2:58 am 
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Hornet Warrior
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No new pics to post--I spent a good chunk of the day today rebuilding the carbs on my GT185.

I did clean up the front wheel on the savage--cleaned the spokes and polished the rim--time consuming, but not photo worthy--I will get back to disassembly this Saturday and get some pics posted up.

If work didn't keep getting in the way, I could make some real progress on this thing :Bang :Bang
Not much tear down left, but the new parts won't be here any time soon, so no use getting too anxious just yet . . .

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 Post subject: Re: ryca build project
 Post Posted: Sun Mar 20, 2011 5:21 am 
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Hornet Warrior
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My chief assistant stopped by my shop today after attending a school athletic function (note the orange and blue hair)--I put him to work tearing more parts off the Savage--he was able to accomplish the following in about an hour:

Front fender removal.
[RSimg]Image[/RSimg]
[RSimg]Image[/RSimg]

Left rear shock removal.
[RSimg]Image[/RSimg]
[RSimg]Image[/RSimg]

Muffler removal.
[RSimg]Image[/RSimg]

Right rear shock removal.
[RSimg]Image[/RSimg]

Admiring his work.
[RSimg]Image[/RSimg]

More tear-down pics to come next week--hopefully, my parts will arrive in the not too distant future and I will be able to begin to document the build-up. :)

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 Post subject: Re: ryca build project
 Post Posted: Sun Mar 20, 2011 7:47 am 
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Hornet Warrior
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Looking forward to this build, should be more kits out there.
There was a recent program where a guy made a cafe racer out of a CX500 and made it look sweet.


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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 21, 2011 4:56 pm 
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Hornet Lord

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Faze wrote:
Looking forward to this build, should be more kits out there.
There was a recent program where a guy made a cafe racer out of a CX500 and made it look sweet.


You mean that joke of a programme called Cafe Racer?
Saw a advert on ebay for a URAL "Cafe Racer" WTF?
That goes against all the rules for what a cafe racer should be.


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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 21, 2011 6:47 pm 
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Hornet Warrior
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Huckero wrote:
You mean that joke of a programme called Cafe Racer?
Saw a advert on ebay for a URAL "Cafe Racer" WTF?
That goes against all the rules for what a cafe racer should be.


Yeah but.

Image


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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 21, 2011 6:58 pm 
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Hornet Warrior
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I wouldn't have thought that a single cylinder cruiser would make a good donor for a cafe bike, but once you strip a bike to its bare essence, it's kind of like having a blank canvas to work with.

Anyhow, for me, it's as much about the process as it is the product, even though I think the end product will be a cool/fun/unique bike.

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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 21, 2011 11:26 pm 
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Hornet Lord

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Mr Faze that is a Honda CX500 not a Ural 650.


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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 21, 2011 11:31 pm 
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Hornet Lord

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bikertrash wrote:
I wouldn't have thought that a single cylinder cruiser would make a good donor for a cafe bike, but once you strip a bike to its bare essence, it's kind of like having a blank canvas to work with.

Anyhow, for me, it's as much about the process as it is the product, even though I think the end product will be a cool/fun/unique bike.


Yup it's stripping it down to the bare essentials. Less is more.


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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 22, 2011 7:34 am 
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Hornet Warrior
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Huckero wrote:
Mr Faze that is a Honda CX500 not a Ural 650.

I was relating to the bike I mentioned, and the 'joke of a programme called Cafe Racer', produced this CX!


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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 22, 2011 10:26 am 
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Hornet Warrior
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Image

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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 22, 2011 10:26 am 
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 Post subject: Re: ryca build project
 Post Posted: Tue Mar 22, 2011 10:27 am 
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Image

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 Post subject: Re: ryca build project
 Post Posted: Mon Mar 28, 2011 2:35 pm 
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Hornet Warrior
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Not much progress to report this weekend--my chief assistant's posse showed up at the shop for some basketball, so I lost my help. I did manage to pull the footpegs, forward controls, and kickstand. I also pulled the exhaust pipe to prepare for a thorough cleaning. Front end lowering kit and clip-ons are being shipped--parts will start going back on soon--stay tuned.

[RSimg]Image[/RSimg]

[RSimg]Image[/RSimg]

[RSimg]Image[/RSimg]

[RSimg]Image[/RSimg]

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 Post subject: Re: ryca build project
 Post Posted: Wed Apr 20, 2011 5:54 pm 
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Hornet Warrior
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Get the chief assistant back in the workshop!!!

I wanna see this beastie transformed :)


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 Post subject: Re: ryca build project
 Post Posted: Wed Apr 20, 2011 7:48 pm 
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I have a few pics I'll try to get posted up, but we lost some of our momentum recently--parts should start flowing from RYCA any time, so that should spur us on to keep the project moving forward.

Stay tooned . . .

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 Post subject: Re: ryca build project
 Post Posted: Thu Apr 21, 2011 4:20 am 
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Hornet Warrior
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Tank and rear hub prior to being shipped. Tank was stripped of paint and will be cut down, welded back together, and painted black. Rear hub was removed from rear wheel, cleaned, and will be re-laced to a larger diameter wheel.

[RSimg]Image[/RSimg]

Drive pulley received some cosmetic attention:

[RSimg]Image[/RSimg]

Rusty, scratched exhaust pipe was taken down to bare metal with a wire wheel and painted in heat resistant header paint:

[RSimg]Image[/RSimg]

The front end lowering kit and clip on bars have arrived--I hope to get those mods done before my tank and other parts arrive--I was hoping for this weekend, but lots of travel on the agenda visiting relatives for the Easter holiday--we'll see . . .

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 Post subject: Re: ryca build project
 Post Posted: Mon Nov 21, 2011 3:59 am 
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Hornet Warrior
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OK, after losing momentum on this project (long story), I am now back at it. I have all of the parts and will take some pics before they start going back on--stay tuned.

This photo shows the seat tubes being prepped to be cut:
Image

This photo shows the seat tubes cut and ground smooth:
Image

I have removed the swingarm to be powder coated--it goes to the powder coater this Wednesday. Once I get the swingarm back on, the rear wheel and shocks will follow:
Image

Most of the new parts are in the boxes seen in the background of the last pic--my next post will show some new parts. :) :) :)

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 Post subject: Re: ryca build project
 Post Posted: Mon Nov 21, 2011 10:29 am 
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Faze wrote:
Huckero wrote:
Mr Faze that is a Honda CX500 not a Ural 650.

I was relating to the bike I mentioned, and the 'joke of a programme called Cafe Racer', produced this CX!


..I actually quite liked that program - it was on a bit of budget but there were some wicked transformations using the ethic that these are 'purists' machines - ie. single / twin engine, minimal frame, wheels and clip ons and not much else...didn't they do a CB919 conversion ? - Eric Bostrum did a test ride on it and the front wheel collapsed I think (ouch)... probably the best was a Yam SR500 (?) - I'd love to do something like that (I just need a garage the size of my house rather than my 10 x 12 concrete shed that's got two bikes crammed in it !!)

Rock on those dudes who have a dabble...

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 Post subject: Re: ryca build project
 Post Posted: Wed Nov 23, 2011 4:06 am 
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Hornet Warrior
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Swingarm sandblasted and ready to go to the powdercoater tomorrow

Image

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 Post subject: Re: ryca build project
 Post Posted: Fri Nov 25, 2011 4:35 am 
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Hornet Warrior
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Location: Ogden, Illinois, USA
Here are some of the new parts ready for installation:

Tank
Image

Seat
Image

Side Cover
Image

Rear Shocks
Image

Hardware to connect rearsets to frame
Image

Muffler
Image

Lots of family/work obligations slowing me down, but I will document the progress as parts go on. :) :) :)

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 Post subject: Re: ryca build project
 Post Posted: Fri Nov 25, 2011 12:35 pm 
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Now that's some progress JMA. One burning question; Other than a break for the midwest riding season, it took you seven months to post up again. The shame of it all. :rasp Now let's get a Boy's Club Mod Party together soon. :Beer

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 Post subject: Re: ryca build project
 Post Posted: Fri Nov 25, 2011 5:30 pm 
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Hornet Warrior
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I have no excuse, other than being an LAI. :Bang

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Last edited by bikertrash on Fri Jun 15, 2012 3:51 pm, edited 1 time in total.

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 Post subject: Re: ryca build project
 Post Posted: Tue Dec 06, 2011 7:52 pm 
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Hornet Warrior
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I pick up the swingarm this week, so hopefully parts will start to go back on soon.

I did work on one small part this week--fork brace fabbed from inside of the stock fender:

Image

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 Post subject: Re: ryca build project
 Post Posted: Thu Dec 08, 2011 5:57 am 
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Swingarm picked up from the powdercoater today--hope to get back in the shop this weekend!

Image

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