Kevin Brown's Café  Racer Project

 

                                                             

I am a pastor in a retirement community and have observed that those people who had considered their retirement are delightful, while those who had not pondered life after work can be awfully cranky. I determined that I would fall into the former category and tried golf, which left me more homicidal than pastoral. After some other false leads it occurred to me that it would be fun to return to passions of youth and so I began to cast about for a “project” bike. At first I thought chopping would be cool (what Boomer does not secretly dream of joining Billy and Captain America on their sojourn across America?) but quickly realized that the geometry required for proper trail is such that a slight miscalculation would result in a bike with less than satisfactory handling properties. Might as well just climb up the church steeple and take a header off the roof.

Eventually my search led me to the London of fifty years ago and the Mods and the Rockers (in 1979 The Who produced Quadrophenia, a story of these groups). The Mods favored tricked out scooters and sharp threads (think Beatles in their early American appearances) while the Rockers were working class kids who wore leather, loved rock n’ roll, and rode motorcycles (ala James Dean). The Rockers, aka “Ton up Boys” (a ton is 100 MPH) stripped the bikes, beefed up the engines and raced from café to café. I loved the concept, the history, AND the fact that I have not seen old school Café Racers in Phoenix, so my education began.

Lesson #1: there is a lot of over-priced crap out there. After many bum leads I finally connected with a delightful guy who had a 1978 Honda CB 550 for sale. I checked it out and other than grime from a trip to Alaska and a bit of oil seepage (all the inline four’s have that problem) it was in great shape. So in February 2009 we struck a deal, the bike moved to Rio Verde, I scrubbed and de-gooped until my hands were bloody, and the odyssey began. The bike was licensed in California, so the first task was to get her registered here in Arizona and following a compression check, new plugs, oil & filter, battery, one failed emissions test and lots of tinkering, by late March she had a title.


I tend to the cerebral, so could not begin the next step without reflection. The quest in Zen and the Art of Motorcycle Maintenance was to find Quality, as Pirsig struggled with the dichotomy of Romantic vs. Rational. I thought that rather than opposites, the Romantic Soul (say, an idiot with little idea of what he was doing) could be united with the Rational Mind (consisting of a Clymer’s, a digital camera with which to take pictures of the correct assembly, and the entire household supply of baggies into which to deposit parts) to create a new post-Modern synthesis which might be that Quality which haunted Pirsig. Of course reflection is often accompanied by copious amounts of alcohol ...

Deconstruction began. With WD-40, wrenches and an occasional hammer the parts began to come off: luggage rack, turn signals, pegs, fairing and then had one of Chris’s “Oh sh**!” moments. There was a small bag crammed between the fairing and the triple tree and inside the bag were a bazillion wires going nowhere. I grabbed my Clymer’s and a wiring diagram from bikebandit.com but of course none of the colors described resembled the colors of the wires sitting in front of me. So I just sat and stared, thinking, "Now what?" No solution presented itself, so I decided to worry about it “later” …


Off came the tank and seat along with the front wheel and forks. I got the forks repacked and with help from Mr. Clymer and my digital photos everything went back in place. Each night I surfed the web making choices: Clubman or clip-on? Full tank & seat assembly or just a bum-stop seat? What about rear-sets? Often decisions were reached by my wife’s diligent accounting of just how much this new hobby was costing.



At last the parts arrived and assembly began. Lesson #2: there are about fifty wrong ways to put clubmans on a bike. I tried them all before finally figuring out how to mount them so one can actually turn without banging into the gas tank. The same is true with rear sets, which involves more geometry and removing a very long bolt that just happens to anchor the motor to the frame. But with trial and error and the help of my son Brian, we got the bike re-assembled enough for an engine test. At one point during re-assembly I had Brian spin the wheels while I checked the brakes and after the fiftieth spin his patience was exhausted: “We’re not even sure if it will start.” “Yes,” I replied, “but if it doesn’t start, it won’t kill me. If it doesn’t stop, it WILL kill me, so keep spinning!”


April 17th was test day for the almost-a-Cafe Racer. One of the greatest sounds in the world is that of a re-assembled engine actually starting, and with cylinders firing sweetly I kicked her into gear and took off. Lesson #3: If you have throttle, you use throttle. She ran great, so of course I pushed the limits and blew a gasket. So the return trip was foot-powered rather than horse-powered, and I endured the wits driving by while shouting "I thought YOU were supposed to ride the BIKE" as I pushed her home. Let the record note that I took names and the day I retire as a pastor, ass-whuppin's will be forthcoming.

Which brings us to Lesson #4: there is a happy balance in these old bikes, and when one upsets that balance by replacing some things, other parts, not unlike small children, shout “Me too! Me too!” Sigh. So back apart she came.

With the engine working again and the body painted (thanks to Bart Iden for the name of a good painter) the assembly into an official Cafe Racer continued. The tank, headlight bucket and side panels went on with no problem but the "bum-stop" seat was another matter. Finally, after multiple trips to the hardware store and a bit of re-configuring, the seat settled into position.

But of course the friggin' headlamp didn’t fit into the headlight bucket, so it was off to the junkyard again. And awaiting me was Lesson #5: Later comes. My “bag ‘o wires” still needed a solution.

By early June Brian found a headlight bucket that fit, a friend figured out which wires connected to what items, I completed the Checker Cab motif, and we fired her up again. I took her out for a maiden voyage and received three more lessons: 1) old bikes are just waiting for a chance to show their stuff; 2) I am very grateful that braking technology has improved during the past thirty-five years; and 3) a Cafe Racer is a young person’s bike. I rode for forty minutes and then needed ten minutes after dismounting simply to stand up straight. So now Brian owns “Mellow Yellow”, our ode to the British working class.

But the bug has bit, so if anyone has a project bike just sitting in their garage, my proletarian urges remain .
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