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Discussion Starter #1
Hello Everyone!



I wanted to share my very first custom build on here as well as get some advise and help from everyone. I'm a pretty handy guy and this will be my first total teardown and rebuild. Something I've been wanting to do for quite some time now. I've been following this site for years even before the switch, mostly just reading and didn't post much. So I wanted to thank every one for all the great posts and info on here, it really inspired me to do my own build.



Shall we begin?



My bike before the teardown had some simple mods: 14-47 sprockets, bigger main jet, shimmed needle, FMF, and everything else stock. I am going to do a hybrid of sorts for my build and am looking to go for something of a hollow moddy / off road mix up. I'd also like to gain some performance, with out going over the top. Perhaps a WEB cam and some new springs? Also upgrade the clutch, and air box complete with a K&N just like a hollow modded bike. I plan on going slowly and just taking it step by step and see how she ends up...



So far she's pretty much all disassembled.



Check out the frame and head with the valves. Looks like it was running really lean to me....



Any Thoughts?





IMG_0858 by Richard Todd Giordanella, on Flickr





IMG_0860 by Richard Todd Giordanella, on Flickr





IMG_0864 by Richard Todd Giordanella, on Flickr



I'll keep posting up here as I make progress.



Woo Hoo!
 

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Hello ToddyG,



I am essentially doing the same thing as we speak. I am a total novice, so I am trying to fly by the seat of my pants. Anyway, tell me about those stands you're using to hold the TW up? From what I can gather so far, it looks impossible to do a build up without something similar...



-DCTW
 

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Discussion Starter #3
Hey DC,



Thats great that you're doing the same thing! The stands are automotive jack stands I picked up at harbor freight last summer. Honestly they have really come in handy, and cost just a few bucks.
 

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Discussion Starter #4
Made a bunch of headway this afternoon:



I was able to get the engine out of the frame and begin to disassemble it up on the work bench, exposing the stator and clutch, which is one of my main concerns. The clutch on my TW after the gear change and jet/pipe combo slipped like a hot teflon buttered pan, so I am planning on replacing it with barnett clutch plates and springs to chinch out the problem. I also was able to grind off all the extra tabs to make for a cleaner look after I get the frame powder coated. The swing arm and front forks poped right off as should and it really made me start to think about some nice suspension upgrades. All the possibilities, limitless in the minds eye, until time and money pop into the equation.... SO for now I'll put it on the back burner and focus on the task at hand. Pick'd up a nice Athena gasket kit off of EBAY for the rebuild.



So far so good.





IMG_0902 by Richard Todd Giordanella, on Flickr





IMG_0903 by Richard Todd Giordanella, on Flickr





IMG_0905 by Richard Todd Giordanella, on Flickr





IMG_0906 by Richard Todd Giordanella, on Flickr
 

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Discussion Starter #5
Here is a screenshot of the clutch plates I'm planning on using, complete with part numbers.



I got the idea from someone on here long ago and took a screenshot of just the part numbers, and can't seem to find the thread and were it was originally located? Thanks of the hook up TW forum!



So who is running these? How are they holding up?





Screen Shot 2012-02-07 at 7.46.16 PM by Richard Todd Giordanella, on Flickr
 

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This is awesome!!! I hope one day to buy a second TDub (a beater) to tear down since I would kill it.




Please post everything!



Thank you,

Adam
 

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Discussion Starter #7
Hey Adam!



I'm stoked as well.



It's funny I ended up getting a 1990 beater to build up and ended up doing the build on my 07.. What the? Wait a minet......



Kinda funny.



Honestly I realized I would rather build up the one with disk break, newer style TK carb, etc.....



Will post some more progress soon!
 

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Discussion Starter #8
I want to share some inspirational photos of some TW builds and bikes that I like. I do release I should have started this thread with these pictures but, if feel it's ok to add it in now. Right?



Please take a look and tell me what you think!





_cfimg5387315715284688629 by Richard Todd Giordanella, on Flickr





4645440418_6cc017a5c3 by Richard Todd Giordanella, on Flickr





1987-yamaha-tw200-9w by Richard Todd Giordanella, on Flickr





yamaha450lg9wp by Richard Todd Giordanella, on Flickr





yamaha_xs650_street_tracker by Richard Todd Giordanella, on Flickr





DSCN6731 (Medium) by Richard Todd Giordanella, on Flickr
 

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I like that first Japanese street style bike with the hollow look and that last bike with the white plastics.... But they are completely different and would have different uses



What kind of riding are you planning on using your TW for? You might have to get a second TW so you can have both
 

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Discussion Starter #10
Tee Dubs,



You're right! All the bikes pictured are for different types of riding. And to provide more detail info, let me explane what and why I like each of these pics and perhaps how it can relate to my own build.



In order of each pic:



1. I really like the color scheme. The black rims with the silver/metal spokes. The overall black theme with the tank being a more of a accent piece, being white with the red TW in bold really popping out. SO I guess this one is more inspirational in the form of style.



2. This one solely for the use of the honda rukus head light with guard. I'd like to do the same on my build or something similar.



3. The plastics on this one really stand out to me, although I am not a fan of the tank shroud. I do however really like the rear fender, and how it exposes more of the exhaust system. And of course, you can't leave out the lifted front fender.



4. On this one the pure simplicity is very appealing, less is more. Engine, Frame, Wheels, Controls, Go! Form and Function.



5. On this 650 street tracker, I really LOVE the inverted forks, and dual disks... I'm tooling around and drafting my current trees so I can fully undertand them, and then making a new set for the YZ80 forks I just picked up.



6. Lastly, this build seems well executed, and thorough. To many times I've seen great bikes that are kinda half way there, or parts missing, or not enough. This build seem to be complete. A vision fully executed. A quality I'd like to demonstrate in my first build..



So all in all, its really a mix of all different characteristics from all types of machines that I'd like to translate into my own work...
 

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Each of your pictures has excellent design features.

As you said, many bikes look unfinished but your examples do look complete.

I believe too many builders don't decide on what they want so they incorporate features of several styles they like.

Which looks unfinished or just plain wrong.

However, if that look becomes popular then that new style becomes a style of its own.



Example: Who first put knobbies on their HD chopper custom street bike?

But now it is not uncommon to see pure street customs that are hardtails (no rear suspension) with knobbie tires.

To me it looks dorky but most street customs look idiotic to me.

I like the beauty of function and most customs are miserable to ride, if the foolish owners ever do ride the things.



Have you seen the "Chain Bike" custom?

There is NO FUEL TANK on the bike, the rider wears a backpack fuel can.

Stupid to the extreme to me.



Decide on what you want your bike to be and follow through!
 

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Discussion Starter #12
Well said JAG. I agree. I also must say that in the end it's all about enjoying yourself, and making your bike how you want, no matter how good/bad finished/complete it really is.
 

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Discussion Starter #13
Made a mock up out of cardboard for the new battery box. Right now it has room for the stock battery, wiring harness, and has a cut out for the K&N to sit next to it. It's nice to see my thoughts in 3D, which helps me create just the box I need and want. I know now after doing this first one, its already time make some changes. The plan for this new box is to function as:



1. Stock sized battery holder

2. Store the wiring harness

3. Shield the K&N.



First round looks good! Check it out. And let me know if anyone out there has any thoughts, ideas, tips, etc... Thanks!





IMG_0911 by Richard Todd Giordanella, on Flickr





IMG_0913 by Richard Todd Giordanella, on Flickr
 

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Why reuse the stock battery? It is huge and heavy. Accommodating it will detract from the hollow look you are seeking. I would use a smaller SLA battery. You can still use the electric start and it looks much, much cleaner.



From my view of your current box and plans to use the stock battery, you are going to need some stout sheet metal to make it work. You are also going to need some stout mounts for the front of the box to attach to the frame.



For shielding the K&N and rear shock you can build a separate mud guard.
 

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Made a mock up out of cardboard for the new battery box. Right now it has room for the stock battery, wiring harness, and has a cut out for the K&N to sit next to it. It's nice to see my thoughts in 3D, which helps me create just the box I need and want. I know now after doing this first one, its already time make some changes. The plan for this new box is to function as:



1. Stock sized battery holder

2. Store the wiring harness

3. Shield the K&N.



First round looks good! Check it out. And let me know if anyone out there has any thoughts, ideas, tips, etc... Thanks!





IMG_0911 by Richard Todd Giordanella, on Flickr





IMG_0913 by Richard Todd Giordanella, on Flickr
I might have a spare battery box I got from Japan hold up till I check out work where I might have put it in my locker
 

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Discussion Starter #16
Soar Thumb-



I was thinking the same thing. That the stock battery is way heavy and cumbersome. I was thinking about a sealed gel type battery, but what is this smaller SLA battery you mentioned? I haven't quite figured out how the hollow mods get away with running no battery? Is it just a smaller battery tucked away under the seat? My year doesn't have the kick starter so the ability to retain the E start is a must...



Rising Sun-



That sounds great! thanks for looking and keep me posted if you find it, would love to check it out!!



Thanks for the feed back guys!
 

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Soar Thumb-



I was thinking the same thing. That the stock battery is way heavy and cumbersome. I was thinking about a sealed gel type battery, but what is this smaller SLA battery you mentioned? I haven't quite figured out how the hollow mods get away with running no battery? Is it just a smaller battery tucked away under the seat? My year doesn't have the kick starter so the ability to retain the E start is a must...


Check out my build thread linked below in my signature line. It shows exactly what I used and how i rigged it. Wire in a battery tender pigtail to make it super easy to keep the bike on a trickle charge. My e-start works with this set-up.



Your box looks like a good start and +1 for building your own. But you will need to have more support than just lipping over the rear brace. There are numerous ways to do it, you just will have to play round with what works for you.
 

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Soar Thumb-



I was thinking the same thing. That the stock battery is way heavy and cumbersome. I was thinking about a sealed gel type battery, but what is this smaller SLA battery you mentioned? I haven't quite figured out how the hollow mods get away with running no battery? Is it just a smaller battery tucked away under the seat? My year doesn't have the kick starter so the ability to retain the E start is a must...



Rising Sun-



That sounds great! thanks for looking and keep me posted if you find it, would love to check it out!!



Thanks for the feed back guys!
I am sorry I got totally dug in a work today and forgot to look in my locker. If you want to run no battery you have to have a kick start and a thing called a Battery lesser
This device circumvents the battery totally.



 
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