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Discussion Starter #1
Moving the build here since, it's well... A real built :D

Here is the begining https://www.customfighters.com/forums/showthread.php?t=136436

And that's were I'm right now








Mods done so far and price of each one:

XT 500..............................................................565
SV650 first gen forks (used).................................130
SV650 first gen Front wheel axle (used)...................30
Front wheel spacer..................................................6
Cafe racer seat (new)............................................35
Fittings for the subframe........................................56
Tubes and metal sheet for the subframe...................25
Subframe welder cost 1..........................................90
Subframe welder cost 2..........................................10
Chopping the stok subframe.....................................0
Headlight (new).....................................................47
Clip-ons (new).......................................................21
Honda GC125 fuell tank (new)................................105
Fuel tank rubber mounts (new)..................................6
Bar end turn lights indicators (new)............................9
Mufler (new)..........................................................51
Yamaha YBR125 speedo drive (used).........................24
Yamaha tank decals (new).......................................12
Harley fork boots (new)............................................5
Bar end mirrors (new).............................................15
Front brake rotor (new)...........................................80
Front brake pads......................................................0
Botom oil line (used)...............................................12
Top clamp (used)....................................................40
Chain adjusters (used).............................................10
GSXR 1k K3 clutch line (used)...................................12
Paint......................................................................45
Front wheel hub with spokes (used)..........................120
Gaskets, o-rings etc for the engine (new)..................195
Wheels spokes and bearings (new)...........................230
Rear foot pegs (used)...............................................15
Custom oil line.........................................................22
Central lock switch (new)..........................................40
SV650 left caliper (used)...........................................45
TT 600 headers (used)..............................................70
Rear caliper repair kit (new)..................................... 25
Fenders (new).........................................................40
Velocity staks (new).................................................45
Truck side marker light (new)....................................10
Flywheel cover (used)...............................................45
Timing chain (new)...................................................60
Anchor points welding...............................................20
Exhaust valves (new)................................................40
CDI box and rear fenders mount welding.....................20
Seat cover...............................................................50
Ergal bolts...............................................................10
Aluminium cylinders, indicator inserts, filter adapter......60
Midpipe...................................................................65
4 screw valve adjusters and carb tuning.....................100
Koso speedo (new)..................................................125
Tail light (new).........................................................35




Total 2928


Sold stock parts:

Fuel tank..............................................................80
Tail plastics ..........................................................45
Seat....................................................................30
Forks...................................................................50
Front caliper.........................................................30
Front brake rotor...................................................30

Total 2663


And a screenshot with date from my phone

 

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Discussion Starter #2
Subframe is done by me












Disassembled the bike, cleaned the frame from the unwanted tabs - remaining tubes of the subframe and degrease all the parts





The oil line leak but someone fixed it by his own way. How needs the manuals after all :D





And you should remove the swing arm to fit the chain slider since you can fit it like this? :doh:






Stored the parts and I will try to catch up the welder today to finish the subframe



 

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Discussion Starter #5
Made brackets for the seat and mufler today. I had the catalyst mounts from a K8. Chopped the one and weld it to the subframe




Also made a pair of brackets for the seat but I didn't take pictures from the procedure.
I took some pictures after I weld the brackets but it's 23:00 here now. I will try to take some better at the sunlight.




Copped the brackets of the seat





And cut the plate to make room for the mufler. A curved piece will take it's place. Needs to weld it and the subframe it's done.









Here is the seat and the mufler bolted to it's final position



 

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Discussion Starter #6
I've bought some used parts from a local store. An oil line, found chain adjusters in beter condition than mine and a top clamp with the central lock in the midle, so I can place the tacho and speedo left and right. But, it isn't compatible with the triple tree I've got. I have to buy it's pair now and the paint it. Also bought a new cluch line and ordered a pair of mirrors.






I didn't like the front tabs of the subframe so i cut it a litle





This week I will send it to the welder for the last time and next is paint
 

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Discussion Starter #7
It was about time to return to my build. I was with gastroenteritis and painkillers for my waist. After that I wasn't in the mood to do any work, so the last week I was trying to recover myself.


So I went to the welder for the last time to weld the last bit of the subframe







Bought some primer and paint. It was late the afternoon when I was done with it. The frame came up really nice I can't say the same for the subframe. It have some imperfections at the finish. The good thing is that the imperfections are to the upper place and the seat will hide it. I will try to smooth it down with a polishing brush. By the way its my first paint job.













I still have to paint the fork boots, footpegs, swingarm, dog bones - link and some other bits.
 

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Discussion Starter #8
Happy new year to all!!!

I tryied to fit the 320mm brake rotor I had bought but the wheel hud didn't want to collaborate. After a lot of research google point me to this site http://www.oem-cycle.com/YAMAHAYZ250BIKEID.shtml and it looks like that the whell hub is from a WR400F which have ID 118.5MM brake rotor.

I was thinking to sell the XT brake rotor and buy a new one for my whell hub or buy a new whell hub. So I've found a XT hub with spokes for 60$. I was planing to chainge rear and front spokes anyway cause mine are rusty and a set of new spokes for one wheel cost 60$ here, so that was a bargain



 

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Discussion Starter #9
After a lot of rainy days, today it was the first cold but shinny day.
Took frame and subframe out to get some pics.
The frame came out really good and the under section of the subframe too








But the upper is a mess
TBH I don't realy care. I won't redo it, the seat will cover it so all good :D






The previous owner of the bike told me that he had rebuild the engine 10.000 km earlier, but it was leaking oil at the botom of the crankcase because his engineer didn't seal it properly.
With all this bondo to the oil lines and to the crankcase plug I wasn't so sure about that.
So I decided to see the condition of the engine. I bought seal gaskets, some o-rings, crankcase plug, a torque wrench 4-30N and the tools to clean the valves.






The engine was in good condition like he said and I didn't do the valve job. It cost me 10$ any way so no big deal. The gaskets wasn't new so he probably assembled the engine with the old gaskets :doh:
Cleaned the crancase and assembled the engine back






Stored the engine for now and I will clean the sealing compound later. The crancase covers will be painted black gloss like the frame and I'm thinking fresh up the crankcase with a litle gray paint.

 

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Discussion Starter #10
Ok, after a lot of rainy days, finaly, I maked to finish the painting from some othes parts.
Removed the old and rasty spokes from the weels and cleaned to paint those later.
All the parts came out realy good and glossy so I'm happy with it.












Assembled the frame with the engine, swingarm and suspension but it was late at night and had to get some rest

 

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Discussion Starter #11
Time to move on the wheels. Cleaned everything with duco thinner and masked








And painted with the spray gun like I did with rest of the bike.
The front hub was in good condition, so no paint for it.
I know it's not that durable like powder coating, but I have a tight budget.
I have already bought a small powder coating system and I'n on the build procedure of an oven!
But antil I get ready with it, my spray gun will do the job.








Ι get the wheels to a tire shop this noon to assembly the spokes and tomorrow I will have it back
 

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Discussion Starter #12
Wow a F-U! Was that so shity paint job on that wheels?
Well here they are, assembled






Now I have to chainge the bearings. I thought that the XT hub had a 17mm axle.
I was wrong. It is 15mm, But.
I had to put some parts together to see how it will look like










Bolted the clocks at the stok mounts of the top clamp. I don't like them, they stick to much high.
I will try to mount them a litle lower. Maybe at the same height of the top clamp.

Here is my getto tool I've make to remove the bearings.
I've found it from an other forum.
I know that my english are not that good so I've took some pictures.
I think it's a swing arm pivot from a CRM but I'm not that sure.
Anyway it have 15mm diameter so it's exactly what I need.
I cut it to 4/4






Took an old bolt and sharpen it at the end like a wedge






Heated the hub and hammered the bolt in to the axle





After that with a lilte hammering to the back side of the axle, the bearing is off the hub.





Next stop to the SKF shop
 

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Discussion Starter #13
I bought new bearings and sealer
Bored the ring in the middle to 17mm





The old bearings aren't that bad, the grease looks like rust. My phone just don't take good pictures at the low light






I've also bought those cheap rear foot pegs. I'm not sure If I'm going to use them but it's good to have an option

 

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Discussion Starter #14
Ok, the bearings are in and the wheel is out of center.
The XT hub is bigger and before I get the wheels for assembly I didn't take the time to measure it.
I thought that it will be the same :doh:






There are two options that I'm thinking for now.
1) Reassembly the wheel with the other hub
2) Remove the speedo drive and clocks and buy an other with a magnet on the wheel.
I like those clocks and I don't want to remove it for now.



Any way I need a break from this. Started working on the headlight and clocks.
I've made a bracket for the headlight. It's almost ready I just have to paint it.
Also moved the clocks lower and closer to the top clamp and took the bike out to take some pictures.
















Feeling already beter. I might remake the brackets to move the headlight a litle lower and closer to the forks
 

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Discussion Starter #16
That's a late update. This weekend done some work.
I had to fire up the engine to make sure that everything was ok after the assembly of the engine.
Well it wasn't everything ok, white smoke come off the exhaust :doh:
Took the head off to replace the valve seals. I had to do it the first time. You know, do it right or do it twice





Next was the carbs





Fired up the bike and it's working good, but with out the mufler the bike was very loud. Next time I will upload a video.
I'm not sure If I can clean the headers. I will try it before I buy an other.
I've bought a new central key switch, stripped the wire harness to figure out how many MTW connectors I need and ordered from corsa technic. They should be here in two weeks.
Here is the central key switch installed





Worked a litle to the headlight brackets too. It's a litle lower now but I can't move it closer to the frame. I need some room for the speedo cable. Not 100% the way I want it, but not bad at all.





And now it's time for pictures :D:D:D





 

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Discussion Starter #17
I bought a left sv 650 caliper for the sv forks. Painted sv and rear stok XT calipers, stok front master cylinder and clutch lever mount.






Finaly I replaced the wheel hub. Painted in black and send it for assembly.
That lead me, to go back to the stok diameter of the brake rotor. Now I need to find an oversized disk for this hub, cause this rotor is very disappointing to watch after the 320mm I had...






The caliper is bolted to the original mounts and here you can see, how small is this rotor. The stok sv650 rotor is 290mm I think.









Trying to fit the battery and the rest of the electrics. I need to be ready when the connectors arrive so I can take care the wiring loom.

An a pic just because

 

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Discussion Starter #18
The connectors arrived, time to DW






The worst part of the build. For me at least..






I was trying to add the terminals to the bar end indicator lights, but the wire coulden't handle the pressure of the crimping pliers.
Too cheap and thin. Here it is compared to a piece of the bike's loom






So I striped down the indicator lights to replace those wires. Job done, much better now.






The front half loom is ready. Tested all and working properly






Now I have the other half to take care.






And that's what trashed so far

 

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Coming along very nicely. You're putting in quality time, for sure!

Great photo documentation, by the way.
 
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