Thoughts on "The Teardown"

I like eggs.  So I know that if you wanna make an omelet you've gotta break some.  Same goes for your bike project.

The teardown is were you get started.  If you're bike is as rough as my '74 XS650, you're going to be taking it all the way apart to the frame.  here's somethings to keep in mind:

• Take pictures first! 

It may seem obvious now, but in 6 months it will be hard to remember just how that odd bracket went on.  A few digital pictures is a good way to remember how stuff goes together

• Go slow, and work in stages

This is the basic teardown, so don't worry about doing the detail stuff like taking your carburetor all too bits.  Just get the main pieces off in sections so you have a clean slate to work with.  Think in term of "systems".  Fuel system: carbs and tank, Electrical system:  gauges and wiring harness, Power System: the motor.  Try and keep each "system" more or less in tact but get it off the bike and set aside in a safe place where you can work on it later.

• Bag and label everything

Nothing is worse then trying to assemble your bike and digging through a pile of loose fasteners looking for that one oddly shaped washer-thingy.  Bag and label stuff.  Steal a sharpie and some ziplock baggies from your kitchen when the wife isn't looking...

• Be patient, don't force it...

If it's an old bike, some stuff will just need to sit and soak in WD40 before it will want to loosen up.  If something doesn't come apart right away, step back and take a second look.  Most bike make sense how they go together, so if something does come off, you're probably not doing it right.

For my Yamaha XS650 I had it down to the frame in about 2 hours (other guys can do it alot faster).  I left the wheels on so I could still roll it around the shop.

Here's how my XS looked after I was done with the basic tear down:

Next we get to talk about cleaning parts...

Basic Build Strategy

I'm lucky that I work with a gentleman that builds custom show cars.  In discussions with him, he gave me a good 10,000 ft view of how to organize a build.  Here's an overall view of my buildplan:

• Phase 1: Teardown
• Strip everything off down to the fram
• Clean parts that are to be saved
• Sell extra parts on Ebay
• Phase 2: Engine Overhaul
• Motor disassembly
• Modifications
• Rebuild
• Phase 3: Rideable Build-up (minimal paint)
• frame mods
• electronics
• custom controls
• suspension
• Phase 4: Teardown Part II
• Prep for paint
• Phase 5: Final assembly
• Powercoating and Paint
• Detailed assembly

Why not do finishing and paint as I go?  I want to make sure the bike is riding and working good before I go to all the work of paint and finishing parts.  I would hate to paint the frame then have to go back mess it up cause I need to reweld something or add a bracket.

Phase 1: Donor Bike and Teardown - Tips for Picking Your Starter Bike

My project began life as a very badly beat up 1974 Yamaha XS650.

In wanting to build a cafe racer, I chose a Yamaha XS650 for a few reasons, these are good test questions to consider before purchasing any old bike for a build.  Here is my reasoning for picking the bike that I did...

• Cost

I was able to get donor bike for $50 from a junkyard.  Cash only.  As Is, Where Is.  Obviously, if you're doing a build on a tight budget, a cheap starter bike helps.  Since I knew my final product would be highly modified, I didn't have to worry about cutting-up something that was in good shape to start with

• Age & Condition

Part of reason I wanted to do this build, is because there is nothing like the thrill of seeing a engine roar to life that was previously a rusted hunk of trash.  I such, I was ok with the VERY poor condition of my bike.  Also, I knew I would be modifying the motor, so having something that was not running wasn't a problem.  I would caution against going with something much older than the mid-70s as cost and parts availability becomes an issue.

• Availability of Parts

This makes ALL the difference.  DO NOT buy a bike, no matter how cheap, that is so rare you can't get parts for it.  Ebay is great, but won't get you everything you need.  I like my XS650 because Yamaha built virtually the same motor in the same bike from 1969 to 1984, therefore it is easy to get parts.  Also, it is so popular, there are several companies that offer new parts and custom bits for them.  This is a GREAT help.

• Uniqueness/Collectability

No matter how cool it might be, please do not cut up a classic.  It might be tempting at the time, but again, it costs more than its worth.  There was nothing special about the '74 XS650 I picked up so in chopping it to bits I wasn't destroying a piece of moto-history.

Here's a pic of the bike right after I got it home: