Mashermoto's big street tracker adventure

[mashermoto]

Man...its been so long since I got some quality time in the garage But today is different Below is what ol' Masher got done today



Here is a shot of the tracker so far. Notice the rear wheel. I scored an 18" SR500 rear wheel at the local salvage yard. It uses a 17mm axle, so I can use the FZR swing arm axle and not have to find bearings that will fit or have an axle made. I think this is a huge improvement over the looks of the 16 inch wheel



This modification was necessary due to the XS1100 forks. The stock fork stops weren't thick enough and the right hand stop allowed the forks to hit the tank. So I welded a piece of metal on top of the stock fork stop. Life is good again



The Hot Wings seat is now permanently mounted to the stock seat pan.



As you can see here the seat opens just like the stock seat. Eventually I will have the seat slide rod that locks it in the open position...AS SOON AS MRW70 MAILS IT TOO ME! Oops...sorry MRW...didn't mean to yell at you



Here is a shot of the seat mounts. I got tired of trying to line up holes and welding nuts on the bottom side of the brackets. I couldn't get the holes to line up for a good fit and the nuts distorted badly after welding. So I took a different route.



Here is the back bracket mount. After I got the bracket set correctly and welded in place, I set the seat back on and marked the hole location I had pre-drilled in the fiberglass. Then I drilled and tapped the holes. Those big beefy screws fit nicely



This is the front two mounts. They really allow the fiberglass seat to mount flat and solid.



Here is my next challenge The FZR swing arm fits a little too snuggly for the stock rear brake master cylinder. I'm posting that one out on a new thread for help, but I'll post the results here.

[mashermoto]

Hi-De-Ho good neighbors! That's Tim the Tool Time's neighbor's greeting from the show Home Improvement. Loved that show.


I've been away from the board for awhile because I've been working on the Tracker. Whooo Hoooo ;D

Below are some new pics...I'll try to get them to the recommended size



OK, first of all, I had trouble with the rear brake master cylinder in my last posts. Here is the solution. As you can see above the adjuster rod now fits between the frame and swing arm.



Here is how you do it. This lever that the brake pedal attaches has two bends in that flat part that attaches to the adjuster rod. Flatten the bends out and that moves the rod closer to the frame. That foot on the end is so that the pedal adjustment screw can be used to adjust how far up the pedal is allowed to move. Other than the foot I welded on, these parts and installation are still stock.



The other modification is to grind a little off the master cylinder mounts.



Here is what it looks like finished.



This was a fun modification...mounting the pipes.



These are a set of pipes that Burge sold me, which is probably the best deal I have had offered from a contact from this site. Thanks Burge



The pipes were designed for both headers to run along the right side of the frame on the outside, then bend upward and in front of the swing arm, ending at about the rear axle. It just didn't give me that warm fuzzy feeling, so I cut the headers off at 32" and gave them a bend by hand here and there so that the left side header runs under the frame and the right side comes out straight on the right outside of the frame.



It amazed me how well the pipes mounted up. I only use one flat bracket to mount both pipes to the outside center stand mount. My only regret is that I can't use the center stand but now that I have checked it, the mono shock setup won't allow the center stand either.



I got spacers fabed for the SR500 wheel and I'm in the process now of getting the XS1100 front and rear brakes aligned.

My box-o-parts from Mikes XS should be here Friday, so more pictures to follow.

[snuffy]

hey moto! what the heck is that rear tire off of anyway?looks like a cheater slick off a model a ford;)..........snuffy

[mashermoto]

Snuff, that tire probably could be used for such purpose ;D The only tread left is on the side. Whoever had that tire was either the neighborhood burn out champion or never leaned more than 2 degrees left or right

[snuffy]

looks like your coming along real well.bike looks great!i'm going steedy by jerks.got my frame back from buddie that powder coated it.did it in a light grey.looks to good!every thing i bolt up to it looks like crap next to the new pc frame.

i was makeing good progress on it till i had the shifter go out on my other bike,a kawasaki concours.its my main ride in summer.eight hours to tear it down to replace a 4 dollar spring!

next up for the 650 is to replace the swing arm bushings,and head bearings.and then set the motor back in the frame.at lest the motor looks good.

keep up the play by play on your tracker it gives me inspration;)........snuffy

[mashermoto]

Hi De Ho good neighbors ;D

I haven't been in the board for a few weeks, but that is mostly because of the work in the garage...and that's always a good thing ;D

My mock up work is all but complete. I have the bike torn down and almost have it ready to go to powder coat. I discovered that I forgot about fabrication on the side stand, so that has to be finished first. Shouldn't take long.

I recently told my sister about a building tracker, and how my tag name for them is Mashermoto Street Trackers. She replied: so this first one is a Moto Proto? Well...she's a smart butt... but I liked it enough to adopt the name for this one

So here is the Moto Proto with most of the mock up completed.



Here is a shot of the left side...



Right side...



Front side...



and Back side.



The forks, triple trees, wheel, dual disks and fender are from the 79 XS1100 special noted in previous posts. The fender was a mangled piece-o-crap when I started, but it straightened out fairly good. I bobbed the front and back. Due to some dents that just won't come out, I'll have to fill and paint. No big deal...I've got some ideas for the paint scheme that should work out.



Here is a shot of the number plate mount I made. The container on top is for wiring. The light and light mount are from Mikes XS. I made the container because that light housing is real tight. My wires would have to be packed like sardines with out it. The wires are accessible by removing the number plate.



Burge gave me some grief about my big orange turn signals So I got me some mini signals and made a mount to fit on the lower triple tree clamps. You can see the rear signals in the photo posted above. BTW, thanks Burge...I don't know what I was thinking



You're probably asking: "Masher, why the hole in the side plate?"

Well...I'm glad you asked ;D I cut up the stock side covers and used them to mount the side plates like the stockers.



I push the knob in and give it a turn and the plates come off. That way I can access everything behind them without any wrenches.



Pamcopete, if you are out there...and I know you are...the box shown is where I plan to mount the 277 re-phase electronics for the ignition you designed. Not long now till I start that project



And last but not least...here is the Web Cam I got back through the mail. It's a hard weld 277 re-phase 59 grind. I got it for the low to mid-range power and also because the 59 grind can use stock springs. I have more about the cam in another post.

Well...that's all folks! At least till the next round of fun

[pamcopete]

I'm just glad to be a small part of a great project! Keep up the awesome work!

[CornbreadRed]

Just thinking.. If you plan to finish the number plates off with ..well, numbers.. I wonder if you could find that (mylar?) material that is used on city busses nowdays. -Where it covers the whole bus in an advertisement, but the passengers can still see out the windows?

Use that for the front plate numbers and it would go over the headlight, but still work after dark.. hmmm..

Chip

[mashermoto]

CornBreadRed I thought Corn Bread was Yellow ;D Just kidding

I don't plan on putting numbers on the number plates. The front plate will most likely have some type of design like the Kenny Roberts bumble bee theme. The side plates I plan on having some type of Mashermoto Street Tracker emblem.

Hang around and I'll post pictures later

[mashermoto]

Here is one more progress picture.



I got the frame and miscellaneous parts back from powder coating. It all turned out good and I'm glad I had it done that way.

I was really not looking forward to heaving the motor into the frame, and was seriously considering building a miniature engine hoist. But while looking through the Sunday newspaper ads I found where Pep Boys was selling the full size 2 ton engine hoists for about 140 bucks that also came with a 40 buck mail-in rebate. So for about 100 buckers I bought one It worked great ;D Just strapped the engine up with some tie downs and rolled it right in the frame.

If you can get your hands on an engine hoist, I highly recommend using it

[jeepurze]

looks good M&M . great attention to detail. picke up a few tips/tricks too. good job, OH and them cabinets in the G-rage I want em!!! HEH HEH.

[mashermoto]

Time again for some updates. As some of you will know from other posts, Masher had a set back when he discovered a starter gear located inside the cases was left out.



This is the culprit. That gear belongs inside the cases and the teeth should protrude through that slot shown in the upper left side.



So out came the motor again. The silver lining in this story is that someone had mentioned Mikes XS had began selling a transmission gear that lowers RPM kinda like an overdrive when in 5th gear. So Masher had to have one anyway ;D



The picture above shows proper installation of the starter gear.



In this picture you can see the original 5th gear I'm pointing at, and the overdrive 5th gear is in the top right had corner of the picture.



Here is a picture of the new gear installed.

So now I'm back to where I left off. I should have some more progress pictures soon.

Later.

[mashermoto]

A little progress was achieved today.



Got the engine back in the frame. Also completed the right side goodies. Kick starter, shifting mechanism, new starter gear rebuild kit, high performance clutch plates, high performance clutch springs, and fixed the tach drive.



And here is the right side case bolted up.

[mashermoto]

Things are moving right along. I've got the wiring complete except for the Pamcopete 277 ignition and some of his trick wiring tips (Killer Starter Switch).



Here is a shot of the right side. You can see that I have basically kept the stock wiring and components.



The left side is the same deal. Stock components.



Under the seat pan is no exception. I even ordered the stock fuse box from Mikes XS. Fair warning to anyone who follows suit. The fuse box requires the stubby 10A fuses that I have not been able to locate at any auto parts store, hardware store or anywhere else. I blew the original and spare that came with the box while tracking down a short in my mini stalk blinkers. Now I'm using 9A fuses. Mikes has the 10A, so I would recommend you buy his inventory out at the same time you order a fuse box Anyway...I am real satisfied with the way the wires fit, and all the lights, blinkers, horn, easy button (starter button) and everything else works just like new ;D



Here's a side view of the wiring harness feeding into the headlight area.



I had intended to have all the connections terminate in the small box area above the light. The box was just too small to hold all of them, so I split the connections between the box and headlight. It still worked out good because the box held just enough of the connections to allow the rest to go in the headlight.



And this is what it looks like with the headlight mounted.

Later

[jeremy]

build is looking great, but I'm kinda concerned about that upper rear shock mount. I don't think it will hold up. the way it is now it just wants to bend upwards and tear the tube on the frame. needs some gussets in a vertical plane or to be rebuilt with tube.
I could be wrong though. if it holds up I bet that bike will be a hoot to ride.