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Leroy's XT500Retro

6K views 44 replies 2 participants last post by  Leroy 
#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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2
#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



 
#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



 
#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
 
#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.
 
#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



 
#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.

 
#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

 
#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
 
#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
 
#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

 
#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
 
#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





 
#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

 
#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

 
#21 ·
I've found headers from a TT 600 in beter condition than mine.
Those headers are a litle larger in diameter and it will gain a litle bit power.
Cleaned and chopped cause the curves at the end didn't match to my bike






Then I had to make a box for the CDI and other electrics components of the bike.
I've make a few cardboard boxes to end to desired one






And finaly






2mm metal sheet






And that was the finished box. I think that's overkill, I want to make an other with 1mm metal sheet






Trying to make the mounts to bolt it in place






But I dont like the right mount. I will make 2 cylindrical spacers like the left one later and done





Now I have to make a box and place the battery here





And the rear part of the wirring loom it's almost done
I used self vulcanised tape but I didn't find a larger one, this one is a litle narrow





Still a lot to do...
 
#22 ·
A new box from 1mm sheet made for the electrics
Still haven't order the spacer mounts











And here is the box for the battery. This is the closest I can fit it to the engine.
To be honest I'm worrying about the battery with heat of the engine and exhaust.
What do you guys think? Please give me your thoughts













Here is where the regulator rectifier will stay





A repair kit for the rear caliper arrived. Installed and everything is on the bike.
Now I need a brake rotor and a fluid reservoir.







And started to make the front caliper adapter, but it was too late to keep working.
So thats it for this weekend

 
#23 ·
It's almost a month now since I've started to work on the electrics and all this time only one thing was spinning in my mind. Where could I fit the fooking battery.
I didn't want to lose the passenger seat, but there wasn't any place on the bike that I could hide it.
So the decision was taken. The passenger could sit on a seat hump :nuts:

Measured






And chopped








And then I saw this






I'll be damned. All this time I didn't want to chop the seat and the solution was exactly there.
I will add a thick layer of foam over the battery and that's it. It won't be comfy like before, but the two seater seat will stay :party-smiley:
 
#24 ·
I went to the welder to weld the box and the left mount






Then I finished the sample of the caliper bracket, the tabs to mount the starter relay and cdi. I also make the right mount of the box but I don't have picture from it. Next time I will upload it.






And prepered the box to accept two quick release bolts






The speedo drive gear holder is ready






Finally the fork boots arrived. This one is the second pair that was shipped to me. The first one had lost on the way.






It's a Harley Davidbon part :LolLolLolLol:






A clamp will fix that.
And at the end of the day I make a chain guard






That's it till the next time
 
#25 ·
I was working on the bike the last days but I didn't had the time to upload the images and update the build.
So I've made a fiberglass box for the battery, added some layers of foam and at the end I've covered the whole seat with an other sheet of foam










And then I nailed the seat cover









I'm not sure if I like it or if I'm going to keep that seat. I will let it for now and work on it later.
 
#26 ·
Two fenders arrived and I'm waiting the 3rd one. There are all the same, I just wave to modify every one to fit the front and rear wheel.

I've bend two 13mm tubes for the bracket of the rear fender






And cut a biger caliper protector to weld the tubes on






Here is the front and one of the rear fenders just sitting on the wheels





For the rear end I will use two fenders. I will cut in half the right fender and fit it there to protect the suspansion and carbs from the dirt. The left one need a mounting bracket. I still work it in my mind but that is what I'm thinking to do more or less

 
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