First start up

A little movie of the first start up after the stripping and the rebuild.

Electrics: Part ONE

One thing where I always was afraid for is the electronics. I didn't have that much electrics in school and I really sucked in it :p. So I looked in the internet for as much information as possible. Really helpfull sites:

http://www.bikeexif.com/motorcycle-wiring

http://cyclesource.com/newsblog/?p=19223

http://www.electrosport.com/technical-resources/technical-articles/how-motorcycle-charging-system-works

http://www.colorado.edu/physics/EducationIssues/podolefsky/electric_motorcycle_howto_wiring.html

But the most help I got from this site ( http://www.rabiator.de/ ) it is a project site from Jürgen how also has a Yamaha Virago XV250. There I found really good plans of the electrics. With the bare minimum of basics of electrics I was able to rewire the bike and let it start. I had however help of my buddy Joachim. This was for me a milestone because I did know that if I can let it run again I can finish the project.

I welded the gas tank mount back myself. 

My buddy Joachim

Putting the engine block back in

After the welding of the hardtail was ready I really could start with the project. The most difficult part is done ( I hope :) ). Now I putting the engine back in ( Heavy as hell ).

Hardtailing: The actual welding

Later I decided that this part had to be very strong and good because of safety. Therefor I chose to let the welding do by a professional. I went with my project to the Old Garage ( https://www.facebook.com/theoldgaragecustoms/?fref=ts ). There I asked him to weld the hardtail to the frame. Afterwards this was a good choice of me and he did a very good job.

Hardtailing: Cutting and fitting the hardtail kit

First I tried to cut as least as possible material away to be sure I didn't do anything wrong. I wanted to weld the hardtail myself. So I puzzled a lot to make the best fit in frame and hardtail. 

Hardtailing: Buying the hardtail

The most difficult part of the whole project is by far hardtailing the Yamaha frame. I searched a lot on internet to find the cheapest, easiest and best way to hardtail my frame.

There are a lot of ready to the last gaiter button hardtails but not for my frame.

Hardtail for the Harley Sportster ( http://www.ebay.com/itm/TC-Bros-82-03-Harley-Sportster-Weld-On-Hardtail-Frame-Kit-Bobber-Chopper-Rigid-/161885784044 )
This is not the good hardtail for me.

Hardtail for the Yamaha XS600 ( http://www.ebay.com/itm/Yamaha-XS650-Weld-on-Hardtail-Chopper-Bobber-Frame-650-rigid-kit-xs-/351570366548 )
This was a long time my best option because I thought its for a Yamaha and it wil fit more Yamaha's than only the XS. I was very wrong about it and I realised it later.

Universal kit ( http://www.ebay.com/itm/TC-Bros-Universal-Weld-on-Hardtail-Hard-Tail-Kit-104-0011-/191706460497 )

Finally I thought I had found the ideal kit for my Yamaha. It is really the best kit for universal purpose. However I have totally no experience with welding so this was going to be very difficult. I always wanted to learn welding so I thought this is a very good moment to learn it myself. I bought a welding post and learned myself a little bit of welding BEFORE buying anything. However I really doubted about the succes rate.

So after the research I decided to go to a specialist. I went to http://www.motortechnica.be/ in Dentergem, a Harley Davidson specialist. There I met Barry the owner of the shop, a very helpfull and friendly man. I had a conversation with him and he told me the universal kit is very very difficult to use especially if you can't weld. So i stepped away from that plan. Barry searched with me for a new solution and we came up with this hardtail kit ( http://www.sportsterspecialty.com/frame-hardtail-weld-on-type-for-1982-2003-harley-sportster.html ). He thought this will fits best on my frame but wasn't 100% sure. I decided to buy it and go for it!

When I finally got it I tried to make a good plan in my head to fit it to the frame. I had to cut some pieces of the hardtail but also from my frame and I didn't want to make mistakes. I decided to do it piece by piece.

Stripping the bike

Stripping the bike is one of the most fun things to do. It took me approximately 6 hours to completely strip the bike. The 2 most important things are the motor and electricity and the frame.  

I want to make a hardtail frame of it so this is a very crucial part and the most difficult operation of the project.