Virgin Bobber Build

[jonathan650]

Hey Guys,

New to the bobber scene, I recently picked up a 97 Yamaha V Star 650 Custom. Completely stock. I didn't hear it run when I bought it as it was -40 out and the bike was frozen solid.

Spring came around and I started work to get this thing running. Cleaned the carbs, replaced some worn carb internals, new plugs, new fuel filter, fresh fuel, and new battery. Got it running after a long time trying and rode it down the street. Next day, again it would start, so the carbs came off for another cleaning. Maybe there was some junk left it the tank that came through some how. After that it seems to start and run fine.

I started pulling the stock parts off such as the huge rear fender, stock bars, seat etc. I threw on some slightly taller bars. And that's how it sits as of now.

The rest of my parts, solo seat, mount, springs, fender, turn signals, mirrors are sitting in my basement awaiting install. The only thing I am still trying to figure out is how I want to mount my fender, and what I should do with the exhaust. Once everything is fab'd up I will be painting the fender, tank, and misc chrome a nice gloss black.

I also want to run a switch so I can turn off the headlight completely at times. Has anyone done this?

Here are some pics for your enjoyment.

When I got it:





Some chopping and mock ups:

[jonathan650]

*Upadate

I decided against the flat fender that I found locally. Wasn't really digging the style, and want to be able to have a passenger at some times and didn't feel that it would be able to safely support one.

I decided to alter the stock fender to slimline it a little. I'm happy with how it came out, I just need to do the " J slam" so there isn't such a gap between the tire and fender.
I also chopped the stock mufflers off the bike and added some curved tips. These suckers are loud!
I added led turn signals up front and in the back to bring the bike up to date a little and get rid of those HUGE stock blinkers. Along with that I added a side mount tail light/license plate bracket.
Took it for its first ride once complete.

[jonathan650]

I have been riding the bike for a few days and have recently started noticing a problem. It seems when it warms up that one of the cylinders (I think its the rear) is cutting out. When I come to a stop it sounds like it is running on one cylinder and sometimes may die at idle, or when I got to take off it has next to no power and sounds like one cylinder, then all of a sudden it will kick back it and run normally. As while im am riding at speed and go to get on the gas it seems to lack power and be running on one cylinder (sounds like it too) until I wiggle the rear spark plug wire and it will kick back in at full power.

I have done some poking around with it, and it seems like the rear spark plug wire is really lose on the plug and wiggles around. If I play with it, the bike seems to run better. Has anyone else had this problem? I'll try to take a video if that would help.

[deathmetaldan]

the loose spark plug boot is a problem of course. But did you jet the carbs for open pipes? If not that would explain the lack of power and possibly some other things.

[Akamm47]

I would lose AIS as well, that will minimize the pops in the exhaust. Maybe think about doing the GAK mod as well,

[jonathan650]

the loose spark plug boot is a problem of course. But did you jet the carbs for open pipes? If not that would explain the lack of power and possibly some other things.

I have not re-jetted. From doing research most people said that for just removing the mufflers and keeping the stock pipe that I would not have to re-jet. But seeing as the way the bike runs, I would assume it has something to do with jetting.

I would lose AIS as well, that will minimize the pops in the exhaust. Maybe think about doing the GAK mod as well,

I will be removing AIS very soon. For right now I am going to keep the stock intake.

Does anyone have suggestions of jetting size? 115 or maybe 117 I was thinking...

[dannyrds]

Can't help with the running problem, but for the light question. If you can locate the wire that does the low beam light, you can cut it and put in a toggle switch, or open the headlight and interupt it there with a toggle switch on the headlight housing

[jonathan650]

Turns out it wasn't a jetting issue at all. The electrical connections on the front cylinder ignition coil had weakened and cracked causing it to lose connection and cut out at times. I replace the end and she runs perfect again.

I did however delete the AIS system which helped a lot with popping. I also did the J-slam to the bike.

Here it is now, all that is left is some paint and to remove those decals.

[JBDad85]

Slick looking ride! Question: how'd you get those tips on there? I chopped the pipes on my '04 and I'm having the damnedest time trying to find something that will reduce down to those tiny 1" pipes. Thanks in advance!

[bodmodmatt]

Like mentioned above just splice into the wiring on the headlight. I have a 03 and used a toggle switch located on the neck. The switch now controls high/low/off.

[Desperado]

Oh man I need to know what you did to your excaust, any chance u could send you some questions via email? Not pm?

[Desperado]

Based on the above picture he posted it looks like he has taken the exhaust off right at the muffler clamp?
I cannot believe that this doesn't need a rejet and or has any ramifications in regards to performance?

[JBDad85]

Based on the above picture he posted it looks like he has taken the exhaust off right at the muffler clamp?
I cannot believe that this doesn't need a rejet and or has any ramifications in regards to performance?

Yeah, I did the same thing with my bike, also had to cut off the pipe that ran in between the front and rear pipes and weld the hole that created shut. I had already done a rejet for the RAK mod (http://www.650ccnd.com/mods/RAK/rak.htm), and cutting the exhaust didn't seem to change anything as far as jetting is concerned. My problem with taking the mufflers off is that the stock pipes (at least on my '04) neck down to about a 1" diameter where the mufflers clamp on so I'm not getting as deep of an exhaust note as I'd like. That's why I'd like to know what he used to get those exhaust tips mounted because I can't find anything that will reduce down to the 1" diameter

[Desperado]

so just because I am super interested in this, when you said...

also had to cut off the pipe that ran in between the front and rear pipes

Where on the last attached picture is that? The entire baffle section? And if so what what "hole" do you talk about when you say you welded a hold shut.

Did you notice any performance issues after the rejet?

[Desperado]

I nearly feel ready to try this, however I am unsure were to cut it, given my last adventure with my front tire I don't think I should angle grind it.

http://www.650ccnd.com/slash.htm