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Old January 8th, 2015, 10:54 PM   #1
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The next project...Virago, flat tracker?

SO, I have had my '82 Yamaha Virago (XV920J) for about 12 years.

it has remained mostly stock for the whole time.

The ninja is as complete as any bike ever will be. And instead of buying a new bike, I decided to finally do what I have been planning for years!

This was a couple years into my ownership.



at that point the only thing I had added was a NOS fork brace.

Before I got the KLR I decided to add some bags and crashbars , but the bags did not last very long, because they made it even uglier!





About 7 years back, I installed a MAC exhaust




when it was time for new tires, I decided I wanted to switch out the stock 16" rear wheel for an 18" rear wheel from an early '80s Yamaha Seca



I bought another virago to scavenge for parts. it wil be donating side covers and starting system at the very least, but most likely the forks gauges and round headlight will be coming along as well!





This project will start with some maintenance and whatnot, and will hopefully end up looking something like this in the future.




I've had a habit of going with the cheap parts, and then going with the good stuff when the cheap parts break. This project, I have decided to go with good parts, no cheap stuff, just spend the money the first time.

Fat tires, 2-1 header with some pipe that sounds good, LED headlight, possibly single carb, freshen up engine as needed, fix stupid oil leak that been going on for years.
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Old January 8th, 2015, 11:01 PM   #2
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Awwww yea....
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Old January 8th, 2015, 11:09 PM   #3
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Viragos are neat bikes. I can't wait to see what you do with it.
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Old January 8th, 2015, 11:15 PM   #4
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Me likey! A set of USD forks would look pretty nice too.
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Old January 8th, 2015, 11:19 PM   #5
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I've been thinking about some USD forks, but the biggest problem is that most of them are too short to keep any sort of clearance. I know it's not going to handle super fast with the 16" front wheel and fat tire,but it will still lean over, and if the engine hits, that usually sucks!

In stock form, with a bunch of pressure in the shock, I already scrape exhaust every time I ride it.

I have also had some adapters made to mount FZR 4 pot calipers on the stock forks, if I swap the rear to the front I may need that with only 1 disc
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Old January 8th, 2015, 11:42 PM   #6
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it looks just like kens bike!
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Old January 12th, 2015, 09:58 AM   #7
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I made these adapter plates a long time ago, so I could mount the blue dot calipers.



if I go with the single brake up front (required if I run the rear on the front) I will most likely get a larger disc, and change up the adapters again.
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Old January 13th, 2015, 07:08 AM   #8
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Just remembered the oil cooler on the parts bike!

You can see it on the oil filter cover and hanging right behind the forks in this picture

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Old January 16th, 2015, 07:50 PM   #9
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Rear wheel to front conversion kit ordered.

This will allow me to mount the 16" rear wheel in the front so I can have the fat tire look!
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Old February 10th, 2015, 08:15 PM   #10
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Started getting the wheel ready to modify, but first I had to remove the beads, the tire had been cut off, beads are the worst part to remove!



My bead pro tools were awesome, and made this nearly impossible job take only about 30 minutes





I got the excess parts removed, and I go pick up my kit this week!
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Old February 17th, 2015, 02:55 PM   #11
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Parts!

The disc adapter, replaces the drive spline. Spline boss must be modified to make it fit.





The drum cover, will keep it looking clean...



And finally, the meats!

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Old February 21st, 2015, 09:45 PM   #12
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Series regulator/rectifier, so I can hope to hide it a bit better and not have to worry about too much heat.
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Old February 22nd, 2015, 08:12 AM   #13
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Damn, this wasn't planned, but scope creep has reared it's ugly head, and I haven't even started building yet! The price was so low, I should be able to cover the cost with selling unused virago parts.
Should be a nice easy drop in with some different bearings. Possibly using the virago wheel, but have eyes on a 16" wheel that fits this front end perfectly.
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Old February 26th, 2015, 11:05 AM   #14
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Suspension is all figured out, I think, the inverted forks on front, and a triumph shock re-spring for the back.

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Old February 26th, 2015, 12:09 PM   #15
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25X48X13 for the top of the steering head,
30X48X12 for the bottom, with the washers, seals and whatnot, I should be able to drop the forks right in!

SV650 caliper up front, bigger rotor from Mikes XS. braking should be fine.
SV650 Controls, Master Cylinder and levers from the old frankenbike.

Possibly the honda headlight as well, I really like that light and housing
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Old February 26th, 2015, 01:28 PM   #16
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looks like you are making progress one or or another. What are those forks off of?
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Old February 26th, 2015, 01:41 PM   #17
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it's a VZ800

Suzuki Marauder


It's one of the few bikes that has long enough inverted forks, and closer geometry to the virago.

but it uses SV650 hardware, so that means GSXR brakes are a possibility
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Old February 26th, 2015, 01:46 PM   #18
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Quote:
Originally Posted by subxero View Post
looks like you are making progress one or or another.
The funny thing is, I have not touched this bike since late fall when we put it in the trailer to store it for the winter!.
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Old February 26th, 2015, 04:00 PM   #19
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Not sure what I think about Cafe's yet... but that final product goal looks SUHWEET
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Old February 27th, 2015, 07:41 AM   #20
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Quote:
Originally Posted by Roark View Post
that final product goal looks SUHWEET
I thought so too, especially since the starting machine is so UGLY
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Old February 27th, 2015, 11:20 PM   #21
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One of the bearing for my front to rear kit was already 17 mm, but the other was 15, so I ended up having to find some rare $30 front wheel bearing for an '86 GSX-R1000

But hey, parts are coming in quickly, and once it warms up, and I can get the bike here, it will start progressing!
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Old February 28th, 2015, 06:40 AM   #22
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I received the front end, and decided that the Virago wheel will fit, I had to find a crazy unobtanium wheel bearing, from a '87 Suzuki GSX-R1100 but it will slide right on the axle with that!



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Old February 28th, 2015, 10:02 AM   #23
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I got bored. Mounted the tire just to see what it looked like.
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Old March 1st, 2015, 07:25 AM   #24
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What is the front end from?
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Old March 1st, 2015, 07:43 AM   #25
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Quote:
Originally Posted by verboten1 View Post
it's a VZ800

Suzuki Marauder


It's one of the few bikes that has long enough inverted forks, and closer geometry to the virago.

but it uses SV650 hardware, so that means GSXR brakes are a possibility
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What is the front end from?
Post #17
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Old March 1st, 2015, 03:49 PM   #26
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Post #17
Sorry about that. Missed the post.
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Old March 3rd, 2015, 05:48 PM   #27
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I took some time today to get the rear wheel prepped for the adapter. Once I get the other wheel stripped down, I'll get them refinished. The goal is to have all of the bolt on parts ready to go when I get the bike out after the snow clears up!.


The guide for cutting



Cut



Trimmed the drum side


Rotor adapter bolted on







New shock



And my steering neck conversion bearings!

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Old March 7th, 2015, 04:39 PM   #28
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Messing around with the front end a little bit. Stole the controls, risers and bar from the Frankenbike.


I figured out that my caliper will work, just waiting for a bigger rotor so I can build my adapter if I need one.
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Old March 11th, 2015, 02:29 PM   #29
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Awesome front end is getting better!

..More goodies showed up today.

R6 rotor, SV650 caliper. Virago wheel. VZ800 forks.







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Old January 7th, 2016, 05:43 PM   #30
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I ended up get the the front end sorted, but never worked on the bike due to being so busy with work (see my "hello from:" thread if in doubt)

The intended goal I have right now is to sell the bike in good running condition, sell the conversion parts, plus the parts bike, to get a decent chink of money for a 2014 yamaha bolt. Then I can build a very similar bike, with much less modification.
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Old January 7th, 2016, 05:54 PM   #31
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Too bad you're so far away, otherwise I would have to ask for forgiveness from SWMBO.
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Old January 8th, 2016, 02:44 AM   #32
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Hah, yeah, that's a bit of a drive to pick up. I've gone to the east coast for a bike, but never the west coast!
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Old March 17th, 2016, 07:40 PM   #33
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Nice build thread, Jason! You should keep that bike just because it is so cool. The Virago's were way ahead of their time, and the CYCOM instrument panel was way cool for the day. I like the way we can swap all the different parts, like the Seca rear... My bike came with an 18" rear, and of course the 19" front. I had swapped wire wheels from a XS650 onto it years ago, as I liked the retro look of spokes, but I have since then put the stock wheels back on it. I will see if i can find a pic of it, and i will post it. I would a parts bike for $100, nd it was compete, so I swapped the OEM exhaust back on it, and I like it. I remember how it reminded me of a Norton Interstate when I first bought it, and how much I loved riding it. I need to redo the forks and new springs, and I also had got a Triumph 955 Daytona rear shock, but the hose cracked off due to clearance issues, so be careful when you install the one. Make sure the remote mount hose clears all the hardware. I only paid $30 for the shock, but hey... I was looking forward to an upgraded ride lol... and you will have to order a weaker spring, that Triumph one is really stiff. I found pics of the parts bike, and this is basically what it looked like stock... only not so old lol.
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Old March 17th, 2016, 07:52 PM   #34
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Oh, I'm back to keeping it, one more ninja to get rid of, and cleaning out the '84 parts bike will get me the space back that I need.

I really do want a bolt though!

I'll build it, it's just going to be slow. I really want it back on the road though.
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Old March 17th, 2016, 08:36 PM   #35
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Thumbs up

Yep these builds always take too long. Glad you're going to see it through.
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Old October 29th, 2016, 08:55 PM   #36
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It's only been about a year and a half. But they are home finally. Too bad I'm in Montreal at the moment.

Dug out of storage


And loaded up to go home!
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Old October 30th, 2016, 09:43 AM   #37
verboten1
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Probably another change of plans, the wheels will be narrower, but, 18" rear, 19" front, a bit more choices for dual sport tires.

xS650 turbo wheels


Shinko 804/805



Or Kenda K761

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Old October 30th, 2016, 12:17 PM   #38
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Kenda

sweet... I was wanting to see this build completed
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Old October 30th, 2016, 12:19 PM   #39
verboten1
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I did quit it, but the other bike I wanted as a project was still $7000, I bought a new car at the beginning of the year, and this was my first bike, I might as well make it nice again! Lol
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Old November 14th, 2016, 09:42 PM   #40
verboten1
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This is moving along rather quickly!

Quote:
Originally Posted by verboten1 View Post
Switchgear figured out. 3 momentary switches on each side with minimal lever mounts and small electronic Speedo on bars.



Electrical system will be m-unit

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Originally Posted by verboten1 View Post
Front wheel/tire is a bit different than the 16" rear wheel up front. This should help with the scrambler look I'm going to try to hit, except for the 2 big rotors that will be bolted to it!



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Spent some time working this weekend, got both Viragos stripped down, the shed straightened up.

I tried out the 16" front end, it was a mistake, I like it.



Stock wheel vs. Seca turbo with R6 rotors (it's amazing how small those look on a 19"wheel)



Both of them are down to the engine. I need to get the covers switched over and get the engine painted up and pretty.



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Tire showed up, had to try it! Starting system harvested from gen2 bike. Carbs torn down and cleaned, I need to get some jets, I don't want stock jetting any more.







And another part of my upgraded electrics



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A wilbers shock on a Virago? Really?


Possible engine theme?



Clean carbs rock.




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