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Tim, you need to move that muffler rearward, and upward. At the relatively modest lean angle shown in the photo, the muffler should not be dragging on the ground. It's a safety issue: if you were to lean a few more degrees, you would start to lose rear tire contact.

Yep, I'm callin' it. We're going for a ride! Meet up on Sunday, March 4th, at 10:00 A.M. in the Bravo Burgers parking lot, 31722 Rancho Viejo Road, in San Juan Capistrano. We'll ride from San Juan Capistrano all the way up Ortega Highway, to The Lookout roadhouse. Ride is open to everyone...

sparkE, how did you connect the fuel line to the water bottle? I was going to do that, but I couldn't figure out how to connect them without leaks.

I rigged up a little test-run fuel tank like so: It holds about a quart of fuel. I have an extra one if you want it. $10.

Sorry I missed your question before, Srgt. Anyway, I ditched the OEM battery box and made a smaller and lighter one out of sheet metal. You can see it in the pictures in my original post, it's painted gloss black, and mounted just above (and slightly to the rear of) the swingarm pivot. It is...

Compression: Check compression when the motor is warmed up, i.e after riding normally for a few miles. The TX500 should have compression in the range of 132 - 142. Don't add oil to the cylinders for your initial test; the oil would give you a false high reading. (Add oil to the cylinders...

It's basically just cutting and welding sheet metal. I didn't do much of it myself; it takes way more panel-forming and welding skill than I have. My neighbor Paul did all the difficult cutting, shaping and welding. I didn't make any photos of my tank being modified, but here's a photo of a...

Hey, Joe! I just looked at this thread after a long time. I watched that video you posted of your bike, it sounded great. What kind of trouble are you having with it? Did you get that reply I sent you a long time ago about the jetting? Here's a copy of it: Re: TX500 build « Reply #423...

Lovehertz: cafe goddess.

Awesome! Give us some photos showing your method for shaping the aluminum.

You can test your welds by filling the tank with water, sealing the gas cap, and then putting a few pounds of compressed air in the tank. A little water will seep out of any pinholes in your welds. Very small pinholes can be fixed with POR-15, of course.

This is how it's done, boys.

Re: TORONTO DTT MONDO PHOTOSHOOT 4 TV Show Pilot... Ha! Looks like you guys are having a blast!

Hey, Joe. I read your post in another thread asking about jetting for short pipes. I ran #135 jets when I had short pipes (stock headers plus 12" supertrapps). Here's the part number for those jets: 99202-601-1350. I paid $5.48 each at my local Honda dealer, a few years ago.

Thanks, Supercafe. I've got my bike partly taken apart now, in order to redo the wiring harness. I'll take a photo when I get that done. Here's a photo of it before I started work on the wiring: DCM, yeah, I'll let you know next time I'm up your way. Feel free to drop me an e-mail if...

Nice bike! Balanced, clean, solid. It looks tough, and ready to rumble. Some suggestions (very minor): 1. If you ever ride the bike hard (fast cornering, late braking) or ride on rough pavement, consider installing a fork brace. Even the stock fender bracket helps to stabilize the forks...

OK, I like a lowered bike as much as anybody. So I'm with you so far. But why take the crude way? You obviously have skills, why not engineer a couple inches of suspension travel into that frame with a hidden monoshock setup? You could make a slammed frame that is very clean and only looks...

I really like the enthusiasm and originality here, but I have to point his out: The little holes that you often see in rotors are for cooling. When a disk brake is used to its limits, there is less and less stopping power (friction) due to the overheated rotor, so engineers started designing...

I was just about to type in all the reasons not to have solid bars instead of shocks. But first I'd like to know your reasons for it.

Why?