2003 XL883 to Ryca Motors Cafe project

Had the Cafe bike dream hanging in my brain for quite a few years now , and while doing some recent research and an offer on a low mileage old 76 Suzuki 360 really put this into motion. The Suzuki deal has been hanging in the shadows for a few months, and the seller just can't commit. So enough is enough, the search really took hold once i saw a Utube short on Ryca Motors and Jay Leno reviewing their Suzuki S40 conversion (www.rycamotors.com) . The search for a donor started. The Suzuki was nice but once I scrolled to the Sportster offer, I was sold on going the Harley Davidson route. SO I began the search. I was able to snap up this very clean 2003 (Ryca has a kit ava for 91-03) with low mileage and the right price (winter prices).





Seems to be a shame to tear it apart, but thats life. day one.



Those long frame rails will be getting cut off and shaved for fitment of mini LED tail signals. The wire loom will need to be shortened in the process.


The slash cut pipes come off next


Ordered my Kit and should have that in the next two weeks. I'll have plenty to do meantime.

Great project bro. I'll be watching!

I'm in! Thanks.

You can probably sell that 100 anniversary paint set for some decent change.

Really can't wait to see how this turns out!

I just subscribed, I'm looking forward to the build and end result.

Very cool. I can't wait to see the process. I really like the underbody exhaust they have on their site.

I'll be interested to see how this goes. One of the few bikes left on my list of possible projects is a Sportster powered "cafe racer".

keeping a eye on this build

I've been interested in these Ryca kits - keep up the good work and take a lot of pictures.

- Mark

I'm in for the build.

Ive got an old Norton Commando that I tried to sell. Too many missing parts for a restoration. But I was able to hang an R1 front end on it and I'm looking for a donor sporty for the drive.

Real interested in whats going on here.

Verde
that would be a trick,to put a HD box behind the Norton engine,you have a 5-6 spd,or 4 and NEVER brake it.
had a 850 commando,3x thru the box in 33kmiles.

ordered up some parts today. I've got the Oberon LED turn signals on order, custom made cnc'd black anodized , unique product, I like the fact that the LED's light both front and back for more safety along with high output for visibility, no lame dim LED's for me.
http://www.oberon-performance.com/acatalog/Oberon_Mini_LED_Motorcycle_Indicators.html

for front duty mounting, going with the GSG cnc'd black anodized turn signal mounts
http://www.streetfightersinc.com/images/GSGTurnSignalBracketCNC.jpg

I have a 5 week wait on those parts due to the custom manufacturing from Jolly old England

Oh, for those in waiting, just wanted to note that the Ryca Motors kit includes new shocks made by Burley Brand http://shop.rycamotors.com/assets/images/productimages/sportstercaferacer/shocks.jpg
these raise the seat height to a comfortable 31" height from the stock 28". I'll take some actual frame height measurements before i put on the new shocks

Any plans to change the wheels?

Roland Sands Design is looking promising

http://www.rolandsands.com/products/morris-wheel-black-ops

Those wheels are nice. Pricey?

Yes , pricy . :eek1

Today,
Took off the pipes, and removed the rear brake master cylinder, along with the foot brake and hardware. The master cylinder will be switched around for the rear sets. Up front I removed the front wheel and the fender. The safety reflectors came off, and the front brake caliper removed. I wanted to prep the lowers for paint (going with a satin black finish) and I wanted to see the upper rubber wipes , so I moved the caps off. All looks well underneath, and no scuffs. I think the wipes can stay.




all looks well in the final drive area, no tell tail leaks


Forks, checking the wipes/ seals. All looks good, some surface prep, with etching primer will be in order then the satin black.



Enough for today.

Todays rainy day project was to prep the forks. First a nice 320 grit sand, solvent cleaning, tape up the mounting holes for the axle and brake caliper, then 4 coats of etching primer, wait 2 hours and 7 light coats of Satin Black. IT came out perfect. I'm satisfied.



After looking for new wheels, and the price involved in purchase, I thought I can resurrect the stock wheels, but primp them a bit... Took off the tire, and started off with a good aluminum polish to see if the rim and slight oxidation will come off. Success was had , so I'm going chemical clean the rest of spokes of the wheel , then tape off the polished lip and primer etch the rest , along with satin black for the rest of the wheel. My guess is they will come out pretty nice, especially since they are in relatively good shape



I'll be tackling that tomorrow . First the front, then the rear.

The contrast between the satin black and polished lip should make for a nice wheel combo. Plus I can save almost $2500 in the process.