TerryK
"Lift up yer' kilt n' let it dangle!"
Picked up this 1978 Yamaha SR500 for myself but it's ended up as a future gift for my 21 year old sons graduation. It's turning out so cool I am now looking for another one for myself! lol
Just before loading it up last spring.
The lump is out and now apart, ready for a 540cc piston, new valves, Megacycle cam, 36 Mikuni carb, stainless exhaust.
Time to get serious.
Stock pipe was freakin' heavy!
Mock up. Honda wheel, GSXR disc, R6 caliper. Only using the R6 caliper.
This is close to what I'll be running on the bike. Believe it or not, the fork swap was easy, the FZR disc is a bolt on to the XS hub, the XS hub is a bolt on to the FZR forks, the R6 caliper is a bolt on to the FZR forks, The SR steering stem presses right into the FZR clamp and the SR and FZR share a common bearing kit. Sweet! This is why I chose the parts I did.
Rusty 1978 SR500 34mm forks bottom, 1988 FZR1000 43mm forks top.
Engine covers prepped for paint.
Low gloss black.
The fuel tank cap will be filled and the new cap will be on the center line of the tank.
Fuel cap is from a diesel fuel tank. I think its funky!
Major set back! Some dumbass managed to drop the engine 1 foot to the concrete floor. Result, cracked and deformed center case.
So now the major tear down begins.
Dont worry, I know what I'm doing!
New/used KLR650 rear wheel and brake components. This wont be as easy as the front wheel, but I don't have to use a different rim/hub/disc combo. I can use the whole wheel and adapt it to the swing arm. A few spacers and some minor machine work on the caliper hanger is all thats required.
Rear mock up.
This wheel is from a 2010 so it's in near perfect condition under the dirt. Rim will be powder coated black.
5.5 inch bottom mount headlight.
Simple flat plate bracket rough.
And after an hour of filing and sanding. Sure could use a milling machine in my garage! lol
Perfect.
XS650 hub painted and ready for spokes.
Hack and slash night in the garage.
After. Now just need to work it smooth and paint both fork legs low gloss black. Cleaning off all the unnecessary tabs and brackets. Aiming for 250-260lbs dry weight.
At Tonights weight reduction pile. I;ve probably taken off 40 lbs so far.
Progress! Front wheel is pissing me off so I went back to work on the rear. Fabbed up the caliper bracket and got all the spacer sizes figured out. Just need to groove the hanger and weld the corresponding stopper on the swing arm.
Engine is coming together. Just waiting for the new valves.
Special bearings arrived today. Who knew Mitsubishi alternator bearings would end up in a custom motorcycle front end? Spacers fabricated and it all bolted up great. Now waiting for the rims and stainless spokes.
Mikes SXs provided the stainless spokes and powder coated aluminum 18 in rim. Got so excited to lace this wheel that I forgot to take pictures of the process!
You know you want this wheel!
Just before loading it up last spring.
The lump is out and now apart, ready for a 540cc piston, new valves, Megacycle cam, 36 Mikuni carb, stainless exhaust.
Time to get serious.
Stock pipe was freakin' heavy!
Mock up. Honda wheel, GSXR disc, R6 caliper. Only using the R6 caliper.
This is close to what I'll be running on the bike. Believe it or not, the fork swap was easy, the FZR disc is a bolt on to the XS hub, the XS hub is a bolt on to the FZR forks, the R6 caliper is a bolt on to the FZR forks, The SR steering stem presses right into the FZR clamp and the SR and FZR share a common bearing kit. Sweet! This is why I chose the parts I did.
Rusty 1978 SR500 34mm forks bottom, 1988 FZR1000 43mm forks top.
Engine covers prepped for paint.
Low gloss black.
The fuel tank cap will be filled and the new cap will be on the center line of the tank.
Fuel cap is from a diesel fuel tank. I think its funky!
Major set back! Some dumbass managed to drop the engine 1 foot to the concrete floor. Result, cracked and deformed center case.
So now the major tear down begins.
Dont worry, I know what I'm doing!
New/used KLR650 rear wheel and brake components. This wont be as easy as the front wheel, but I don't have to use a different rim/hub/disc combo. I can use the whole wheel and adapt it to the swing arm. A few spacers and some minor machine work on the caliper hanger is all thats required.
Rear mock up.
This wheel is from a 2010 so it's in near perfect condition under the dirt. Rim will be powder coated black.
5.5 inch bottom mount headlight.
Simple flat plate bracket rough.
And after an hour of filing and sanding. Sure could use a milling machine in my garage! lol
Perfect.
XS650 hub painted and ready for spokes.
Hack and slash night in the garage.
After. Now just need to work it smooth and paint both fork legs low gloss black. Cleaning off all the unnecessary tabs and brackets. Aiming for 250-260lbs dry weight.
At Tonights weight reduction pile. I;ve probably taken off 40 lbs so far.
Progress! Front wheel is pissing me off so I went back to work on the rear. Fabbed up the caliper bracket and got all the spacer sizes figured out. Just need to groove the hanger and weld the corresponding stopper on the swing arm.
Engine is coming together. Just waiting for the new valves.
Special bearings arrived today. Who knew Mitsubishi alternator bearings would end up in a custom motorcycle front end? Spacers fabricated and it all bolted up great. Now waiting for the rims and stainless spokes.
Mikes SXs provided the stainless spokes and powder coated aluminum 18 in rim. Got so excited to lace this wheel that I forgot to take pictures of the process!
You know you want this wheel!
