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Author Topic: Teledan's XT500 project  (Read 14338 times)

Offline Bert Jan

  • Posts: 1786
  • Holy Modification Batman
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Re: Teledan's XT500 project
« Reply #10 on: Jul 19, 2013, 14:59:01 »
Nice fleet dude// damn shame about the white one.. bike is looking fine!

Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #11 on: Jul 19, 2013, 16:39:36 »
Yeah it was pretty sad when the white D90 was wrecked, she's a lot bigger and meaner now though :)  The white Disco is my daily in the winter and when I am not riding but the trans just crapped out so I think I am going to sell it and get something better on gas.    I'm having a blast on this bike, its super fun to ride.  Just did my 1000mi oil change so that makes about 1300mi since the top-end rebuild and shes running strong.  I think my neighbors hate me because of the pipe though :)

Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #12 on: Jun 12, 2014, 12:43:49 »
Its been a while since I have updated this.  I have mainly been trying to gather parts.  Picked up a set of XS650 forks yesterday.  Here they are mocked up with the wheel, an FZR600 rotor, and an R6 caliper:



Also built a new pipe:



I also picked up a stator, rotor, CDI, and Regulator from an SR500 and I will be building a new harness for it.  That probably wont be until next winter though, I am having too much fun riding the bike to tear it apart right now :)
 

Offline DreadRock

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Re: Teledan's XT500 project
« Reply #13 on: Jun 12, 2014, 13:59:23 »
Watch the spacing between the wheel and back side of the caliper ! When I did mine I used a sv650 caliper so I could mill down the back side to give more space !

Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #14 on: Jun 12, 2014, 14:08:19 »
Thanks man, it looks close but I think it will be ok.  If it is too close I may end up using a 320mm rotor and see if that gives me enough room.

Offline dualero

  • Posts: 217
Re: Teledan's XT500 project
« Reply #15 on: Jun 17, 2014, 11:51:22 »
What was the mod you did on the crankcase? What's the purpose of it? Following this build! Keep it up!

DH900sl


Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #16 on: Jun 17, 2014, 12:24:32 »
Thanks!  I installed some set screws to hold down the rocker shafts so they wouldn't rattle around.  What happens is that the bores in the rocker box get worn out of round so the rocker shafts start moving up and down in the bores.  I drilled some holes from the top and tapped some threads and then used the set screws to hold the shafts down.  It is somewhat common on these motors and Yamaha actually re-designed the rocker boxes and shafts on the later motors to prevent this from happening. 

My motor was real noisy before:

http://s587.photobucket.com/user/teledan/media/My%20XT500/2698CFEA-CBFE-4E20-B14B-83C72EC11744-6827-0000174FAF5CA195_zps1be3232e.mp4.html

And this was after the mod:

http://s587.photobucket.com/user/teledan/media/My%20XT500/6A16809A-6DE0-4A7F-9C5D-B5802D464F8F-3446-00000AEEF67D0E59_zps5b0c29f5.mp4.html

Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #17 on: Feb 09, 2015, 13:42:19 »
Sorry, it's been a while since I have posted an update.  I picked up a wheel from an SR500 and I got a caliper from an FZ1



I will be using the caliper hanger from the FZ1 because the rotors are the same diameter but the axle on the FZ1 is 28mm and the XT/SR is 17mm so I needed to make a spacer.  I fired up my old Craftsman 6" lathe and turned this out:



Fits like a glove:





I still need to figure out what to do for the anchor rod and the MC mount.

I also got the front rotor spacer turned out, I just need to drill the bolt holes now.







It ended up being 12mm thick and the rotor is almost dead in the center of the caliper.  Still got a lot to do, gotta paint the triple trees and the front wheel, rebuild the forks, and then wire it. 
« Last Edit: Feb 09, 2015, 13:44:17 by teledan »

Offline teledan

  • Posts: 154
Re: Teledan's XT500 project
« Reply #18 on: Feb 09, 2015, 23:53:17 »
Oh, and my new shinko 705s came


Offline 7aliveatlast7

  • Posts: 516
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Re: Teledan's XT500 project
« Reply #19 on: Feb 10, 2015, 19:35:26 »
Cool bike! Tuned in for this one!