YAMAHA XV920 CAFE RACER

Purchase

I have fancied a V-twin for some time, and had looked as a number of Virago-based cafe racers. So when this US-spec 1983 920J model came up, as a running bike and at the right price, I had to go for it.

Inspection and Stripdown

The bike hadn't been run for many years until the chap I bought it from had changed the oil and given it a quck run up the road. The engine sounded fine so I fitted new tyres and it sailed through its Manx inspection. I then stripped all extraneous items off it and the underlying condition of the bike was pretty good. Even better now it had been put on a 'diet' it looked really slim.

Rearsets and Clipons

All the other builds I'd seen had retained the stock triangular rear footrest hangers for mounting rear-sets, but to me they looked heavy and unwieldy. So I decided to fabricate my own from 8mm aluminium plate, which necessitated the creation of wooden templates to get the sizing, hole positions and spacing correct. The new gearchange linkage required an extension at the rear to lower it enough so it didn't foul the pedal on change. Meanwhile the standard rear brake link bar was easy to attach.

By contrast fitting clipons was simple enough, along with new universal levers and a braided front brake hose.

Tank, Seat and Subframe

Althougjh I'm not normally a bif fan of chrome, for once I could see it being a great look for this bike. I also loved the Benelli Mojave-style tank often fitted to these bikes. These excellent units came from a bespoke fabricator in Wales (Colyn James, 07971 651258), although it took a great deal of trial and error to get the tank in the right place, with foam padding at the rear, and to fabricate and position small aluminium mounts at the sides that were bolted to the frame, and a threaded tube at the front that was welded to the frame. The the subframe was supplied by cafe Racer Webshop, with the seat bolted to it.

Suspension

I stripped the forks and fitted new seals and YSS progressive springs. I also disconnected the air pressure pipes and sealed up the remaining holes. Initially I dropped them down through the yokes by a massive 2" - it remains to be seen how this will affect the handling. Meanwhile at the rear a YSS replacement monoshock MZ456-385TRL-06-05 was a must (456 means 45mm piston, 16mm shaft; 385 means length in mm).

Air Filter

I wanted a small, neat air filter and stubs were not easy to find, but again my local 3D printer came up trumps with a neat solution for little money.

Electrics

A Skyrich LTM21 lithium-ion battery was fitted under the seat hump in a bespoke stainless box, along with a compatible regulator under the air filter. Similarly small LED indicators (using the standard mounts at the front) along with a compliant relay. The relays and associated wiring were all seated on an aluminium plate attached to the underside of the new subframe. A bespoke, lengthy battery-to-starter cable was fitted, the relay now mounted behind the right-hand footrest hanger.

Exhausts

Many such bikes sport a two-into-one system but I much preferred separate pipes, so acquired two moto-gp style end cans. I would have loved to mount them under the seat but the routing and heat insulation would have been too problematic. Acoordingly I mocked up a new system, acquiring appropriate stainless tube and bend/adapter pieces, then had them welded together by good friend and neighbour Steve Ault. Support was provided by mounts extending from the rear of the new footrest plates.