Trophy Based 900 Cafe Racer

The first half of the kit has just arrived! Ill take some pictures later but for now Ill just say that everything looks excellent - shame the bike isnt in a state to start the build up but heyho!!

 

Right - Bit of a long time since I posted - Lots going on at work meaning I was out of the country lots and then fitted a new kitchen at home to keep the wife happy however some work has been done in the mean time!

The entire kit has arrived however to stop myself getting over excited its stayed in it box for now. I want to get the rest of the bike looking nice before building the kit. Otherwise Ill skip jobs

So where were we - I had dropped the engine out of the frame and removed all the casings to send to be blasted and powder coated. The came back looking lovely - I therefore put the engine back together with new gaskets and seals all round and using a black aluminum engine bolt kit from Probolt - they are predrilled for lock wiring which will also happen down the line as I like the look.

The swing arm was also removed - after a fight - which ended up needing a sledgehammer! The bearings were then removed - again after a fight - and it was sent for powder coating - just putting new bearings back into it now and as predicted its fighting!

The wheels were also sent for a powder coat and came back looking lovely when they were a bit horrible before. The colour is divided opinions but I love em so I dont really care. I have done new bearings and dust covers front and rear too obviously!




I have also fitted a new sprocket set and have a fancy gold chain ready to go.

I also looked at the rear engine mount brackets. They have large lugs for the centre stand, but I dont want a centre stand, so these have been cut off and the brackets cleaned up.




With all this in place I put the engine back in the frame and rebuilt the front end.



Now I just have to finish fighting the bearing in the swingarm and then stick the back end back on. After stalking ebay for some time I had a lightly used and good condition Hagon monoshock turn up today which can also be installed.

Then I can open the boxes from CRK and start building the bike!

 

Ok so more work done! Was away with work for basically the entire month of July but found a little time!




Firstly Rear end back on with the new/ebay shock



It looks the part and the swinging arm now looks like the frame! - Why the factory did black frame silver swinger I dont know. All black contrast the engine nicely!

Next up stick the new subframe on. This is part of the CRK kit and is fantastic. It was a little tight trying to get it to fit. It slides into the hollow lower section of the frame and wouldn't drop in. I considered using a large hammer but after a cup of tea I realised that a file was the correct tool as there was some weld on the inside of the frame which was making it tight. Minor filling and it slotted neatly into place!


With that done I couldn't help just sticking the tank and seat unit on to see how it looked!!



I think its going to look great - love the proportions! Amazing that its spent its life as a heavy weight tourer.


I have also now added the battery, rear lights and indicators plus all the wiring - I have wrapped the exhaust headers and also added new silencers, I've fitted the clip ons, Ive ordered a bikini fairing and some fancy billet parts for the rearsets. Also bought new main jets for the carbs and also pod airfilters rather than the airbox but I havn't taken photos of these but will do this week (if anyone is still interested!).

I actually have next week off work so will spend at least a day on the project - hoping to front light on and wired in, get the rearsets and rear brake back on. New grips too. Also refit radiator and exhausts leaving me to do clocks and body work before being nearly on the road! I want to use the bike in the spring but with a push I might have it done before the winter really sets in!!!!

However I had a little wooops on my other bike so want to get that back up and smooth ASAP too!




So much to do!!

 

Thats actually part of the project - Its my first project and have done nothing like this before. My tool kit cost 60 quid from Halfords and had sockets, and spanners. I had screw drivers and pliars etc but and im just buying/borrowing additional tools along the way. Basic tools, haynes manual and taking my time!

 

More photos you wanted - more photos you shall get! Had some time to do some work.

First up I wrapped the headers with black wrap. It was the first time wrapping pipes and i might redo it at some point! It could be slightly neater. I then added my new end cans. I really like the black finish - Too much crome was too common!



They should make a nice noise too!!

Next up I fitted pod filters to the carbs and changed the main jets to suit. Then refitted the carbs and linked up the throttle cable and the choke.

Next up was the clip ons. These are part of the kit but I changed the grips to match the wheels - Also they were called "Bitwell Thrusters" which made me giggle slightly!


Those of you with a keen eye will notice the new clocks too. These were a bit of a fiddle - The kit come with the metal work etc to let you use your old clocks just in a slightly different format. However the clocks of the 900 trophy dont fit. However CRK were great and made some up for the 1200 trophy clocks. I therefore bought the 1200 clocks of ebay and built the now attached.



It did require me to build a new wiring loom for the clocks but it wasnt too bad using my haynes manual and the CRK instructions. I even used the standard connector snipped off my old bike so everything looks fairly seemless! I did have to buy a new soldering iron though!!

I've also fitted new rearsets. You use the ones from the donor bike but add some kit parts to hold items like the rear brake cylinder. However the ones of the trophy dont fit so I bought some off ebay from a sprint. Then added some shiny pegs from china as i didnt really like the standard rubberised ones.




As you can see they have an exhaust hanger on them. which is useful. On the other side I also found the rear brake master cylinder was totally rusty and i was unable to strip it to rebuild so I bought a shiny gold one which seems to fit fine.



I also fitted the rear hugger and chain guard. They are chromed and I quite like them like that. Im tempted to do the front mud guard to match.



New chain went on too!

Finally I fitted the headlight and it works!!



I had to hid much of the loom and connectors but that was easy enough. She is looking more and more like a bike now.

Still to do is refit the rad and fit the exhaust. Refit rear brake. Fit front mudguard, Fit seat, fit and connect tank, then im ready for paint!! Not too much really


I also bought a little fairing and sat it on the bike



I need to cut this to fit and make a hole for the heradlight. Also need to make a frame to attach it to the bike - will likely need some help from someone skilled for that but I have a few mates with appropriate skills!

I'm becoming fairly confident Ill have her on the road for the spring!!

 

Well thank you very much!

However its actually not too bad! The kit is really very good!

 

im sure you will be impressed. the instructions are excellent as is the kit. haynes manual is good too!

 

Small photoless update. fitted the rad and new exhaust. then put some fuel into the cabs and it started!!!!! Couldnt believe it! I maybe should be so surprised as it was obviously a running bike before I started messing but it means my wiring is all good and I havn't messed anything up when i took the engine apart to paint!

exhaust wrap smoked like hell, idle was at about 4k and i found a small oil leak from the clutch cover and coolant leak from the water pump so not perfect but all easily fixed!

Outrageously pleased! ill get pics up shortly. need to do tank seat and rear brake and then its ready to paint! v happy!