South African rebuild of a XTZ 750

[CharlieGreger]

Greetings all, I have just been informed of this forum thanks to Mezo. I have started posting my rebuild on ADVRider as well, but seeing as this is a Tenere specific site, i will be posting here as well. I must mention at the start that I have been keen on doing some sort of a rebuild/replica for years. I used to do rebuilds of old thumpers a while back, sort of a weekend hobby if you will. And i often thought of doing a rally replica of sorts, but never quite seemed to get it together to actually do one. Now I have my bike stripped to the bones and will be attempting to the best rebuild that i can in the budget i have set aside(permission granted from the missus)

So the plan is to turn this...


into something like this..



or perhaps this....



Originally I have always said that i will keep the Chesterfield theme going on her, but the more i see that sexy blue , the more i like it. What are your thoughts on the matter?? Mezo's rebuild of his 3AJ was... well to put it mildly.... fekin stunning, And i am hanging to see the end result of Geoffs little escapade. I'm torn between the two colour schemes really, cant for the life of me make my mind up, so i might actually just flip a coin and let the gods decide.....

[Mezo]

I am so looking forward to this.

Your choice my man, ive done a blue one so id do a chester next time.

Mezo.

[Dirtybrit]

Chesterfield!

[Kaspaas]

Subscribed

I can send mine to you and you can do one of each colour.
I wont charge you for that, as long as you sent mine back after you done

[CharlieGreger]

Right then......

So the plan is to strip her naked and have the frame, swing arm, headlight/front faring mounting frame and a few other bits & bobs sandblasted and then powder-coated. (any idea what the paint colour of the frame is??) respray the tank and plastics either white or blue and have the decals printed and stuck on then do a few layers of clear coat.

The motor will be stripped as i am going to change all the bearings in the gearbox, and any other that might need doing while i am at it. The valves are on their last shim so i will be putting in new valves as well.( $$$$$$$)
I would love to have stainless pipes up front and a different pipe for the back. something a little less bulky. I have the stock pipe on the back and it is bloody huge, and is too heavy. So perhaps a decent aftermarket number that sings a decent tune at 5000rpm

have the carbs cleaned and serviced. I did the emulsion tubes last year, still cant believe the difference in fuel economy.
Braided brake pipes front and back.
new screen( I have a clear one on, but it has a crack in it after a narcoleptic episode in the Karoo during my ride to the west coast earlier this year)
still looking into powder coating the rims
rewire the entire bike so that the fuse box is at the back under the plastic lid that the original toolkit is stored.
mount the reg/rec at the front for a bit of fresh air.
And to respray, fix, renew/replace all those fiddly bits.

Ahh yes, and i am trying to find a full set of stainless steel nuts bolts and washers for the bike to replace all the stock ones. Any idea of where i can get such a thing??

Now then, what i have a need for is a bike stand of sorts. Some kind of gizmo that i can rest my bike on and not have to move it around or ask someone to hold it up while i do something blah blah. So i head off to the local scrap dealer and hand over 50 beans and have all the steel i might need for said stand.

My welding is rather pathetic, so after a few attempts, i finally get the temperature right and the stand comes together nicely....



and then give it a quick once over with a handy can of black spray paint i have in a box on the shelf. Then with much effort and a few choice words, i hoist the heavy slag onto the frame which is a tad higher than i thought i might need.But still low enough to be usable.

[CharlieGreger]

Sorry, I forgot to mention... In the above pic with the little black arrow pointing to the frame. Once i had the tank pulled off, I noticed a crack in the paint. So out came the sander and a crack that goes almost all the way around the tube

I was praying to God, Allah, Buddha and a few others that i would be crack free, but i must have done it wrong. So another expense of having the bloody thing welded. I just hope that after its all sandblasted there are no more cracks to be found.

[55W1985]

I have this picture scanned from a period sport magazine.......
Does this variation look atractive?

[55W1985]

Oooops found this one at the end of the dakar 91 series

[Mezo]

Hmmmm, frame color.

Well there's not a massive choice in powdercoat colors, if you was going to do a Chesterfield id be doing it like Geoff & going white, if you was going down the Sonauto theme the color is Dulux "French Blue" 32725 (that was my color) and is the closest you will get to Sonauto colors.

http://www.sunshinecoast.qld.gov.au/add ... chemes.pdf

The exhausts can be expensive, but if you keep an eye out for some standard cans from something like an old Ducati (aluminum) & then open then up & mod them.
You would need to make a custom front pipe but still cheaper than buying an aftermarket complete system.

The crack in the frame, well it depends how you intend to use it in the future i guess? to do it properly cut that piece out & put a new bit in there,
id personally just weld it up (as long as its a decent weld), id now (once its sandblasted) be looking for the small hairline cracks that haven't yet formed
it to major ones.

Mezo.

[BigEd]

Chesterfield!

Yep, as an old Chesterfield smoker - I agree.

From another SAer to another - GO STORMERS!!!!