Dual Sport SR500

[hunterkey]

Well, Im going to go ahead and post this "build" of my sr500 I'm starting.
I really wanted an xt500, but an sr500 came up for sale in the area for $900 and I grabbed it. These Yamaha thumpers are kind of rare around here, and I happen to think they are an awesome design in their simplicity and performance.
I am going to use the bike as a regular driver, and something I can blast on some light trails and such.
I really want the bike to be capable of long distance rides and adventures though.
Here she is the day I got her:

 

[hunterkey]

sorry the last picture is sideways, idk how to fix that.

So far I have bought new tires (dunlop k70), and since the header was hacked up I was planning on getting a new one. bcthomas on here was selling a white bros supertrapp exhaust and header for the price of a new header, so I jumped on it! Unfortunatly the P.O. of my bike welded the old muffler bracket to the muffler so I need to buy one of those before I can install the new pipe.

When I first got the bike, I did an oil change and replaced the front tire as it was pretty bad, and bled the brakes. I took it out on a 100mile camping trip and had the time of my life. When I changed the oil I found that the drain plug was waaaaayyyy too tight on the sump cover, so I just removed the cover to drain the old oil out. This was good because I got to see the screen, and clean it a little while I was in there. It was bad that I ripped the old gasket and when the oil got hot it leaked alot haha. I had to carry a couple quarts with me for the camping trip. and everything was cool. I have since purchased a gasket.

Here she is on the maiden voyage:

 

[hunterkey]

We went about 5miles into the woods, and that was a ton of fun. I had been drinking and it was dark and I dropped the bike, bending one of the blinkers, scuffing the headlight bezel, and breaking the headlight switch.

I need to pass my driving test on the bike for my license (I only have my permit) before I can remove the blinkers. I really love the look of this bike:

 

[hunterkey]

So, after the trip, I was able to find some more stuff wrong with the bike. The tach didnt work half the time. After dropping the bike, my rear brake wasnt working. and the bike idles high.

As for the brakes, it turns out the piston was seized in the caliper. I finally got that loosened and cleaned up. I also replaced the rear tire while I was back there.

after playing with the carb I think the pilot jet is a little clogged but it there may be an issue with my fuel pump accelerator? After looking at the cost of new diaphragms, and cables, and gaskets, etc., I have decided to just get the vm36. I will post about that once I get it an install it.

As for the tach.... here is what happened:
The threaded portion of the tach assembly had just broken in half?!? wtf... It seems that the intense vibrations from the single cylinder will loosen and destroy some parts along the journey.

 

[hunterkey]

thanks to sonic, on here, he sent me an old tach that was crusty and missing a needle, but did have the threads! I used it to rebuild my broken tach. Here are pictures of that:

 

[hunterkey]

Considering all that here are the things I plan on doing to it:
Mikuni vm36
-new jets
-Cable
-maybe new throttle assembly if needed
-new rubber intake
-carb to airbox reducer

New Headlight switch
Renthal Handlebars
Grips
Shocks
Brake rebuild and maybe drill the rotors
Extra Oil feed line
NGK spark plug boot
Muffler plate
Seat reupholstered
Plastic pieces repaired
Battery
Maybe ignition coil
Maybe Barnett Clutch
Maybe new clutch cable
Maybe new brake lines

I was pleasantly surprised to find the bike has a K and N filter already on it.
also worth mentioning, the side covers need some love if they are going to fit properly.
I picked up this book to help me with g.m. and stuff.

Any advice, clever criticism, and free stuff is very much appreciated!
Also... if you have an xt500 (or tt500) and wana trade... lemme know!

 

[Spitfire151]

I like it! Can't wait to see how it turns out =)

What year?

 

[hunterkey]

Thanks man! It's a 1978 model

 

[Spitfire151]

I dig it!

 

[hunterkey]

So i bought some 13" sportster shocks off craigslist, and the eyelets are too small for the sr. Anyone out there know how to press out the old bushing and install new ones? Should I try to make new ones? I wish I had a lathe... it maybe best to drill these out and install a new metal spacer, preserving the rubber?
thoughts? ideas?

 

[xb33bsa]

sportster shocks will make that thing stiff as hell in the back wont they ?
same length as stock ?

 

[JGHiggins1]

Can you post a pic of the eyelet that you are trying to modify?

 

[SONICJK]

Hey I'm glad that tach helped you out!
Looking good, I love those tires on the SR.
I feel like these things are just meant to be dual sports 8)

 

[hunterkey]

sportster shocks will make that thing stiff as hell in the back wont they ?
same length as stock ?

Well they are adjustable, they were only $40, and the stock ones are super worn out. These are half an inch longer.

I will take a picture tonight

Hey I'm glad that tach helped you out!
Looking good, I love those tires on the SR.
I feel like these things are just meant to be dual sports 8)

Thanks again man! Your bike looks so mean!

 

[bradj]

And on the other extreme the ground clearence on my tt

 

[hunterkey]

And on the other extreme the ground clearence on my tt

Oh man, I would normally be so bummed you hacked up a TT500, but this thing is awesome!!

 

[bradj]

No i didnt, the motor is a tt but i built the frame

 

[hunterkey]

Hey Guys,
I need the muffler mount for this guy.
Anybody have one they want to sell?
It is the circled piece here

 

[Spitfire151]

Any luck on ebay?

 

[hunterkey]

nope.. not on ebay, and it is kinda pricey on oem sites