My T500 started off as a 1971 frame with a 1975 GT500 engine. I love air cooled two strokes so I decided I would like one with modern handling. I thought about building my own frame initially but lack of time and certain equipment dashed that plan. However I did cut off a good chunk off of the frame including the rear engine mounting point and the swing arm pivot area, I fabricated new frame tubes and the swing arm pivot mount to get it closer to the counter shaft centerline. I also used a swing arm from a YZF600 but I cut it and made it 30mm narrower also modified to be a linkless mono shock. The biggest challenge on the bike was to get the chainline correct, for this I had to make my own offset counter sprocket (probably the part that gave me the most satisfaction knowing I made it myself) and machine the rear sprockect carrier from the EX650 wheel that I used.
The forks are from a ZX636 Kawi with a modified steering stem and top clamp. I made a custom adapter to suit the KTM bars and clamps. Rear shock is EX650, I made an adjustable mounting so the ride height can be changed. Rear brake is a modified KTM Brembo unit. Rearsets are modified Triumph Daytona units.
The tank and seat I made from scratch from 3003 aluminum, all done using hand tools and oxy/acetylene welding (I don't have tig). I also made my own expansion chambers which was a lot of work but I got them exactly how I wanted them to look.
The engine has been ported (eric kalamaja, sundial motorsports) and I am running 34mm mikunis with it.
The bike came out exactly as I imagined it would. Now I look forward to giving it a good thrashing on the street and track.
Thanks again to all of you for your support while I have been building this bike.
Cheers,
John.