Flat Track Replica xt500 project [Archive]

Badcat

24th April 2005, 21:53

hi - i'm about to embark on a project and would like to ask for any help, experience, stern talking-tos or parts that you may be able to offer or sell.
i've just bought an xt500 with a ready to assemble engine in bits from trademe
http://www.trademe.co.nz/structure/auction_detail.asp?id=25989456

of course - it's gonna need a load of work and bits...

i've owned a lot of bikes - euro and jap and love singles.
last thumper was a KTM 640 supermoto
http://www.kenkong.com/album/album....d=55&personId=3
and i loved it, but want to build something very minimalist, with much lower suspension, something with dirt ergos, and a nice timeless retro look.
so starting with a good chassis, modernising it with a better front end with a big disc and a 19" wheel.
i love the alloy tank, so will leave the aesthetics, but will build a good motor with a 36 or 38 mikuni RS or flatslide and a custom pipe probably.
will hopefully run a 17" rear 4.5 inch rim as the pirelli MT60 wets on my ktm were incredible - although i have dunlop k180s on my vanvan so am still considering wheel size.
the bike will be a street bike, so i will have minimal and light street equipment.

a couple of inspiration links:
http://www.mulemotorcycles.com/default.asp?page=newprojects&project=Dan%20650

http://atsearch.autotrader.co.uk/WWW/dpage_photoad.asp?id=200511185589746&abname=batmotorcycles&pageid=3&largeId=160137381

as i said - any help, parts or ideas would be appreciated...
ken

Sensei

24th April 2005, 22:29

Great to see ya got a real Single, Have built 3 XT500 TT500 into motards over the years . Putting 540-560-610 kit's into them ,Tony won an auction on Trademe with shit loads of old XT/TT parts on it & Guy I just sold my 81 XT500 to here in New Plymouth is doing up 2 TT500's He has alot of bit's to . They are getting very hard to find & if you do find them the people don't want to sell . If I can help drop me a PM have a few contact's still .

Eurodave

24th April 2005, 22:30

Im building a Flat Tracker based around a 71 Honda CB450 twin
I have the 'glass molds for the XR750 solo seat , a couple of tanks ,front & back mudguards & number plates.If you are interested I can also supply the 5 1/2" chrome headlite & flat track handlebars and a hot cam too, check my profile,cheers Dave

Motu

24th April 2005, 22:44

Look up OWL Morris in the members list - OWL raced a TT500 Flattracker for a few years,held the Rosebank No1 plate maybe 4 times,he changed the wheels and bars and raced it in F3 too.He got the bike back 10 yrs later and rebuilt it,racing it in Pre 89 for a few years,turned into a street bike these days,has just fitted an Omar seat unit.I think it's a bit bent at the moment though.He know his way around XT/TTs pretty well.

Badcat

24th April 2005, 22:48

Eurodave

26th April 2005, 11:56

Ken, heres some pix

Motu

26th April 2005, 12:23

That looks pretty good eurodave,the 450 was a tricky motor for it's day.This is a photo of my brothers XS650 streettracker,he lives in Canada and I'm not too sure what he's done to it lately.

Eurodave

26th April 2005, 12:30

That bikes NICE, Im still trying to decide what colours to paint mine, bloody hard to chose!!

Badcat

26th April 2005, 12:38

below is the kind of thing i'm going for style wise...
of course - it won't be a twin - but a single, but this aesthetic with modern front end, brakes etc.
will poss go for carbon on the seat cowl and guards - maybe even the tank too.
i hope to stay with wire wheels prolly around 19' front 17" rear and use K180s (have these on the vanvan) or the excellent pirelli mt60RS wets i had on the KTM supermoto i had.
I may use a shortened MX from end with supermoto caliper and 320 mm disc, this seems like the easiest way of getting good susp with a minimum of fabrication. Using a sportsbike front end would prolly be a better length - but i don't want to use mag wheels..

anyone thinks i'm insane - i'd like to hear it.
or constructive advice too.
will def. post images as i go....

k

Eurodave

26th April 2005, 12:50

Have you checked out "Omars flat tracker" US website yet ? Lots of flat/street trackers on there, quite inspirational

Badcat

29th April 2005, 17:06

Have you checked out "Omars flat tracker" US website yet ? Lots of flat/street trackers on there, quite inspirational
yep - there's some nice bikes there.
mine will hopefully be more modern and high-tech.
perhaps not a faithful homage - but bugger that.
k

Badcat

1st May 2005, 15:59

well - i drove to tirau and met the guy with the xt500 in bits, paid him and drove it home.
the engine is STUNNING,
rebored stripped barrel
10:1 wiseco 88mm piston and rings (new)
reco head (like a jewel)
bottom end is sweet too
tony (seller_ is a motor reconditioner so it's brilliant.
also came with the rest of the bike - with a kawasaki MX front end thrown in. i won't be using it but i can sell it..
the frame is in excellent condition.
it has an alloy swingarm too!
2 more complete motor bottom ends (in bits)
i couldn't be happier...
the only downside is the tank is buggered, but i new that
now to get that buell WP front end on trademe.....
pics below

i'm hoping to follow this project right through in this thread - hope i don't bore you...

hee hee

k

gav

4th May 2005, 22:51

Nah, mate, be great to follow your progress. You know, you HAVE to finish it now, too :msn-wink:

Badcat

8th May 2005, 07:35

well - here's this weeks progress.
i dropped the frame and swingarm to F1 engineering in hamvegas on friday.
steve's going to check it on their alignment jig for straigthness.
the swingarm needs some chain damage repaired and cleaned up - so he's going to sort it and polish it too.
i won't powdercoat the frame yet - as we'll prolly have to weld on tage for mounts etc - and take off uneeded mounts.

the next descision is the front end.
i have two options - as i want very late strong USB forks:

1 - a sportsbike front end
this will be easier to find, but i'll be stuck with a fixed length and mounting a spoked front wheel will be harder.

2 - a late model MX front
this will need to be shortened from 12" travel to maybe 5, but will give me the luxury of being able to make it exactly the right length. it will also have a single disc, and a spoked hub won't be hard to find.

i think mx is prob the way to go..

so - if you know of a good say, CRF, or YZ, KX RM front end....

more updates as they happen

Badcat

21st May 2005, 12:48

ok - after much delliberation over suspension - i've bought a WR250 for the front end.
i figure (after talking to craig at colemans supension dept) that an MX front end will be easier - as:
i can shorten it to the required length (Going to take the 12" travel at each end down to around 6" and respring and revalve the forks and shock (s)
triple clamps will be closer
bar mounts aleady there
easier to re-lace the front wheel with a 19" rim
the donor i bought is here:
http://www.trademe.co.nz/structure/auction_detail.asp?id=26687109
now i'm seriously considering just transplanting the XT motor into the WR chassis - looks like much less screwing around, it already has discs, monoshock etc. i'll have to have an oil tank made (or use a buell one) but it looks like the wr chassis is lighter and probably better.
also - it's not in bits and all the bearings, seals etc are new too!
will probabaly get tjebbe bruin to do the motor transplant...
also got a 41mm mikuni flatslide on trademe for $200, it's a little big but i'll see how it goes.....

hee hee

k

Ghost Lemur

21st May 2005, 15:17

Sounds like the project is coming along nicely.

Hope you're taking lots of pics during this whole process.

Motu

21st May 2005, 15:46

Badcat

21st May 2005, 16:58

Yikes! I can see the temptation with the WR - Do it!! The TT500 is a big donk though,sits vertical too,the bottom rails my have to be cut out...no worries.Do some creative thinking on the oil tank.....

There were some Lectrons on TradeMe,they'd suit a TT500.

yep - i think i'll talk to tjebbe and see what he thinks.
the wr is pretty nice - and that frame with an old aluminium tt tank and the XR750 seat will be pretty nice... i still plan to do the whole retro look.
as to the carb - i have two standard 36mm roundslides - may start with one of those - and put the flatslide on later if and when i do the xt's cam etc...
as for the oil tank - there's a buell one on trademe for $50. i'll be running a K+N filter so will hopefully have room...
i am concerned about the 6v electrics - what do the classic bike guys do if they want headlights that work?
i have a hyabusa headlight i'd like to use!

k

Badcat

3rd June 2005, 17:05

well - the aliminium tt500 swingarm arrived from repair and polishing - it's pretty damn perfect looking. much better than i imagined.
the frame is on it's way back from being straightened - so that should arrive next week.
f1 engineering in hamilton did both - thanks
then it's time to lace up the yz front hub to the new black 19" rim and look at the feasibility of using the yz rear hub in the xt swingarm (the yz wheel has a new yzf 426 disc brake instead of the xt drum).
after the wheels are sorted - it's off to craig at colemans suspension tech to shorten the yz forks (and powder coat the outer legs)...
then its on to sourcing/making the twin rear shocks - i'm thinking ohlins.
i've decided to use the xt frame - the yz frame is way too small after looking at the size of the xt engine...
anyway - there's the swingarm...

Sensei

3rd June 2005, 19:57

Put a PE400 /250 swingarm in one of my TT580's was mint . 41 carb ? to big
had a 38 in my XT500 & was a bitch . never got it right . went back to a 36 flat side . But was on Avgas ! The Steel swingarm of the XT500 were stronger than the Ally ones even when the motor was standard . But didn't look as good . thats why I went to the PE swingarm . will keep a eye on your progress . :niceone:

Badcat

3rd June 2005, 20:01

yeah - i think that carb is too big.
i'll put it back on trademe, and find a 36 fcr pumper.
thanks for the heads up re swingarm, but i'll use this one i think.
more pics when the wheels and frame are done..
k

Badcat

24th July 2005, 08:17

well, after a very depressing analysis of the parts needed to complete i kinda went off the boil....
THEN, i decided to ask my KB family for help!
i decided than another complete donor bike would make the project much easier as what i had needed SO MANY genuine yamaha bits to complete.
SO, i posted that i was looking for an XT, TT or SR 500 that was complete but damaged was ok.
SPB was very forthcoming, there was one in his family!
i got the xt500 yesterday, it's the the same model as the incomplete one i have, and looks like it will even be a runner with some TLC.
so new plan, looks like i'll use the new complete bike as a the base of the Street Tracker, using the parts i have to repair/upgrade to the level i want.
so - now to get the new rims on the YZ hubs, get the YZ USD forks shortened and then once all the wheels and forks are done, i can get the rear shocks made (oooooh new custom OHLINS.....)
once i have a rolling chassis, i can get the YZ rear hub modified to fit my sexy TT swingarm and the rear disc carrier grafted on, and the rear brake lever, master cylinder etc welded to the xt frame.
All fabrication after shocks will be by steve bridge at F1 i think - he's been very understanding and done such good work so far. So looks like there may be more updates soon! - with pics.

K

30th July 2005, 05:07

.
.
Looking forward to following the progress Badcat. Hope to perhaps see it at New Plymouth on 5th November??
.
.

Badcat

13th August 2005, 21:09

okay.
the GS1200 is sold - so it's all systems go.
the wheels are being laced this week - 19x2.15 front and 17x3.5 rear
Avon has new supermoto tyres in these sizes, so off to Kerry's next week.
i spoke to ONroad last week - they say that pre-vin bikes need previous history of registration. i need to fax the motor registry centre in P.North on monday, and hopefully i can get one of the frames rego'd.
Henderson Motorcycles are getting the motor built, and then the WR250 USD front end gets modified to fit.
then it's the TT500 swingarm's turn to get slightly massaged - to take the disc caliper from the WR.
So, new wheels on, swingarm modded and fitted, and the NEW CUSTOM OHLINS are next.
heh heh...
looking for a left hand RI caliper and a big disc for the front next.
The pro-taper handlebars (Black) are waiting - so is the White Brothers e-series exhaust. will prolly get Custom chambers to make a header - still working out whether to mount the pipe trailbike style or sportsbike style.
will try the std tt500 roundslide, but am leaning towards a mikuni TM pumper flatslide 36mm carb.

Found an australian co that make a 12v and CDI conversion kit too - the bike has points and is 6v.

Oh, and ordered a flattrack seat from eurodave too.

will have pics as soon as it starts to come together - and have attached some pics that are close to how i'm thinking style wise.

any comments appreciated.

k

SixPackBack

13th August 2005, 21:15

was wendy any help K? [pics look good]

Ghost Lemur

14th August 2005, 20:59

Good to hear the project is coming along so well.

Owl Morris

16th August 2005, 21:03

I've still got that TT tank if you're interested --- haven't been here for a while I've been busy building, riding, crashing and rebuilding you know how it goes.

Motu

16th August 2005, 22:22

It's stunning in the flesh OWL,your best version...so far.

Badcat

18th August 2005, 22:05

well - the wheels are away getting laced up - they should be ready next week.
bad news on the road registration front though, i can't register either of the frames i have.
poohs.
so - i have spoken to peter doak at emoto - and he's looking for an sr400 in japan when he's there next week. they were until very recently still sold in japan - so i'm going to try and find one at a good price and use that as a base for the project.
the upside of spending all that money is:
12V electrics - not 6v
CDI - not points
hopefully not staring with a bare frame or scruffy neglected 25 year old trailbike.

SO - the project takes yet another turn, but it only makes me more resolute to finish it.

below are some pics of modern sr400s - they are almost unchanged from the 70's....

Badcat

20th August 2005, 22:27

well - i'd been watching a trademe aution of a badass race sr500 - stroked to 600cc motor in an RGV.
well - the guy broke it up and auctioned the running engine, ignition, carb etc and i won it.

the sr500 has CDI and 12v electrics! and this one has hardly been run.
i now have two sweet motors, one mild and one wild!
hahahahahahahahahaha!!!!
now to get the sr from japan and GET THE THING BUILT!!!

here's the link...
http://www.trademe.co.nz/structure/auction_detail.asp?id=33647325

Bonez

21st August 2005, 08:53

Motu

21st August 2005, 09:44

I remember seeing the one with the drum brake in Haldanes a few years ago.That brake is a copy of the XS1 drum brake,but no SR400 ever came out with them,the first Yamaha single,the XT/TT/SR 500 came out in the late 70s and only the dirt bikes had a drum,and they were smaller with a conical hub.

Badcat

21st August 2005, 10:20

Would be nice to see some in good ol NZ. Anyone import them?
no - they are plentiful in japan - but importers dont bring them in.
average punters want 600cc plus 4 cyl sportsbikes - or 1000cc twins.
will post pics of mine when and if it arrives.
K

betti

21st August 2005, 16:15

nearest ive got to a flattracker, built while workin at aggression performance engineering in england, what ya think?

Bonez

21st August 2005, 16:49

nearest ive got to a flattracker, built while workin at aggression performance engineering in england, what ya think?Looks kewl.

Badcat

21st August 2005, 16:59

nearest ive got to a flattracker, built while workin at aggression performance engineering in england, what ya think?

NICE!!!!!

nice and tidy.
i like the monoshock rear end too!
k

avgas

21st August 2005, 17:35

i miss the sound of a nice single :(
how fast do the really big singles go (600+cc)? can any break 200? would love to build another cafe' racer - but it has to be able to break a decent speed (my last 400 only did 165, and my 185 only did 130). While saying that i dont want to up gear too much, as i still want it to be quick

2_SL0

25th August 2005, 12:51

Badcat, this looks like it is coming along nicely. Im keen to see how it all comes together, as I may do something similar in the future.

Badcat

25th August 2005, 14:24

well.....
i bought another motor....
it's a badass 600cc SR motor (12v and CDI!!) and it's been very expertly installed into an RGV...
it has a stroked crank - new rod and a nice stainless header and can.
the head is very midified i'm told - will strip it down and compare soon..
now i see how nice it is - i may keep the RGV and install a spare motor i have into the rgv - what a sweet little roadbike!

Badcat

28th August 2005, 09:27

hey.
well, peter doak has secured an sr400 in japan - i get all the details tomorrow. the rims (oooh - black excel rims...) are finished and at kerry's for the new "R" compound Avon Supermoto tyres.
the new 600cc motor in the RGV chassis is very cool and seems a shame to remove it - i'm going to try to see if i can register the frame - if i can i'm going to find a dead RGV and build a second bike - a real cafe racer as a counterpoint to the street tracker.

pics to come.

k

SixPackBack

28th August 2005, 10:09

Badcat

28th August 2005, 19:56

well - peter got me a BEAUTIFUL sr500.
i've attached a pic.
it's a 500 - not the much more common 400 version
it arrives october and then the fun starts...
say good bye to:
that drum front brake
the wheels
all the chrome.
that CV carb
that quiet exhaust
hee hee

SixPackBack

28th August 2005, 20:04

nice, seems a shame to wreck it

Badcat

28th August 2005, 20:12

nice, seems a shame to wreck it

trust me - it will look sweet.
and - i'll keep all the orig bits.

k

SixPackBack

28th August 2005, 20:16

trust me - it will look sweet.
and - i'll keep all the orig bits.

k

you will have a serious stock pile of parts at the end?

Badcat

28th August 2005, 20:28

you will have a serious stock pile of parts at the end?

i can say that i'll be OK for spares, yes.
also - as it's a 500 - i'll have 2 spare motors, so will prob build the RGV chassis into a stripped down little cafe racer with the badass 600 and the FCR.

w00t!

SixPackBack

28th August 2005, 20:32

i can say that i'll be OK for spares, yes.
also - as it's a 500 - i'll have 2 spare motors, so will prob build the RGV chassis into a stripped down little cafe racer with the badass 600 and the FCR.

w00t!

Excited for you Ken you have a lot of scope with all the parts

Badcat

24th September 2005, 11:00

well - still waiting for the sr500 to arrive from japan - another 2-3 weeks to go.
the SR/RGV looks like it will be a go too - have tracked down a RGV rolling chassis - hopefully get that next week, so i'll be building 2 bikes:

1 - the SR500 from japan will be stripped down and re-emerge as a retro street-tracker. this will have the mild 500cc 10k motor, and will gradually be warmed over, wiseco 10:1 piston, TT carb, and white bros Eseries pipe.
XR750 seat, maybe an R6 front end and ohlins.
Still on spoked wheels, with avon distanza supermoto tyres

2 - the SR/RGV will also take shape over the next few months.
This will use the badass 600 motor, 41 FCR, white bros cam and custom pipe.
it will be a naked lightweight streetbike, with renthals and minimal bodywork.
i'll probably use my hyabusa headlight on this - kinda like the yamaha naked r6 - is it the fz6?

here's a bunch of links i've been using for inspiration...
http://www.sr-racer.de/japan.html
http://www.motocarrera.com/trackertime.htm
http://www.bikeparts.jp/pedals-suspension-wheel/pedals-suspension-wheel-00031434.asp
http://www.mertlawwill.com/street_tracker.htm
http://galerie.sr500.de/thumbnails.php?album=3

Badcat

24th September 2005, 11:10

http://www.sr-racer.de/Strasse.html
http://www.sr-racer.de/Rennstrecke.html
http://www.sr-racer.de/StrasseII.html
http://www.siue.edu/~rsutton/SR/78-79.htm#Frame
http://homepage1.nifty.com/246/yam_whel2.htm
http://community.webshots.com/album/165262350ZhvFvU
http://www.kedo.com/
http://www.vd-classic.com/EN/realisation.php
http://supermotech.co.uk/specials_4.htm

Badcat

24th September 2005, 11:16

if you can't be arsed with the links...

Badcat

24th September 2005, 11:29

10987654321

Badcat

20th October 2005, 17:25

well - the SR arrived today after biketranz charged me $390 to freight it from chch to auckland WITHOUT INSURANCE.
man - i feel so violated....

anyway, it's 10 years old, and a retro so it looks pretty old and a bit scruffy, but i'm happy with it.
it starts easy, and the wierd drum front brake seems actually very good!
front suspension is REALLY soft, so that and tires is the first priority.
the tank (spare one) and flat track seat (thanks eurodave) are off to get painted tomorrow - and i need to find someone to make some brackets for the seat - anyone have suggestions?
the headlight and instruments are HUGE, so they will be coming off.
it's quiet and smooth, so i'm happy.
in the weekend the Pro-tapers and clamps will go on, as the std bars are very narrow and pulled back. maybe better for some little japanese guy...

more updates soon as the transformation progresses.....

K

Badcat

21st October 2005, 08:22

well - i rode the sr to work today...
the good bits first.

the motor is GREAT, excellent low end torque, and smooth and mechanically very quiet. the bike has done 11k in its 10 year - and it starts quick and runs very well.
the not so good...

everything else.

it's a good thing i'm changing so much of the bike as it's rattly, loose and pretty lame. the bike is probably very good for its type and age, but man, bikes have come a long way since 1978 (the bike is a 94 but it's the same as a 78)
the suspension is soft and skittish
the brakes are ok - but the front suspension is so bad that using the front brake is pretty scary
the handlebars are too narrow and pulled back, riding position is awful.
seat is narrow and tall
the tyres are AWFUL - an ancient metzeler perfect on the fron and an equally antique bridgestone on the rear, i'll be off to kerry to get something good today.
i'll also get the front forks stripped and re-sprung by craig at suspension tech (colemans) i think, as they are so soft ,

i'll fit the pro-taper handlebars and adjust the controls tomorrow, and i think once the bars are sorted and new tyres, i'll feel a lot more confident.

I will say though, that peter doak at EMOTO (www.emoto.co.nz) was wonderful through the whole thing.
my complaints are with the low-tech of the SR as a model, not with this particular bike. I got what i wanted at a good price in good condition.
i just wanted an old lowtech bike, and that's what i got...

stay tuned.

K

Motu

21st October 2005, 08:38

So is the motor the old original SR/XT/TT 500,or is it a different capacity version of the later 4 valve motor? Typical Yamaha to keep the old motor in production if it is.

Badcat

21st October 2005, 09:43

yep - it's the old school 2 valve kick only - with the cute little TDC indicator on the head.
i wanted the old 2 valve, as that's what they raced in flattrack i'm told.
it's a sweet motor - nicer than the SRX i owned.
it's just the rest of it that is a bit scary.

i'm having a ball though!

Kerry is ordering the AM22 sticky stickies for those little 2.15 rims as we speak.

anyone know a good light engineer?
i need some little brackets made....

k

Owl Morris

22nd October 2005, 15:31

These shots may be of some help.
Standard SRs are sad, slow and sloshy. When I rode my first SR project home, I was doing the " my god what have I bought" I couldn't believe it had the same motor as the TT. After dumping the granite Exhaust system, the cast iron mudguards and that stupid carb You start getting a motorcycle.
Is yours mag or spoke wheels?

Badcat

22nd October 2005, 17:19

it's a 94 - imported from japan, there's pics of it a few posts back in this thread.
i fitted the pro-taper MX bars and clamps today - makes A HUGE difference now i have some weight over the front wheel and the levers etc are in the right place.
also dropped the tyres to 30 psi front and 32 rear (was 36 both ends) and put 15 psi air in the forks.
transformed the ride - i feel a lot better about it now.
new tyres next week i hope.
take a look through the thread if you have a minute - all the details are there.
ken

T.W.R

22nd October 2005, 18:53

Badcat

22nd October 2005, 22:35

just a few ideas for you badcat, the biggest thing to making a big single go is cam timing duration ( retard inlet roughly 4degrees and advance exhaust 2-3degrees) and let the bugger breath! :niceone: jet the carb a few sizes, chuck a pod filter on, keep the inlet port rough & polish the exhaust port ! :niceone: , fit a large diameter header pipe on & a free breathing muffler ! :headbang:
check the pics for a couple of ideas. :niceone:

thanks.
i have a spare motor i bought recently - an ex-SOS sr500 - running around 600cc - a new FCR41 and radical head and a white bros e-series muffler ready to go on. will prolly get brett roberts to dyno tune it when its all assembled..
am looking for a cam though... can you recommend someone in NZ?

will do all the chassis mods first - and do the motor once i'm happy with it all before i make it badass.

ken

T.W.R

22nd October 2005, 22:56

Badcat

22nd October 2005, 23:01

denco engineering in christchurch would the men to see! they make them to order, to the specs you want, slotted cam-sprockets the works. specialists with singles e.g. speedway motors . don't know their web addy but contact bob denson ph 03 381-2111 or fax 03 381-2069.
make it mumbo! but don't lighten the crank, keep the horses as clydesdales not racehorses to keep the serious single bang !

yep - right with you on the clydesdale thing.
i picked the SR/XT as it was a old-school big midrange torque beast.
my last single was a 2002 KTM supermotard - i wanted air-cooled and strong down low this time.
the fun's just starting!

k

T.W.R

22nd October 2005, 23:06

haha yeah know what ya mean, if ya screw up its knee in the armpit trick! secret is roll over once, second roll get it on to compression mid stroke then bang it home ( that always worked on the XR500 & the XS850)

Badcat

23rd October 2005, 07:55

here's a pic of the new handlebars- pro-taper CR high-bend.
i used the add on clamps that bolt to the existing bar mounts, but may replace these with proper new entire mounts.
i'll wait to see if i like the extra height that the add on clamps give me.
the difference they make is huge, as the bars that came on it (aftermarket jap) were way to narrow and pulled back for my 6'2 frame.
Bike feels a million times better now.
oh, and that trick of using Hairspray as glue for grips works REALLY well!

- don't tell the duchess i used her fancy hairspray, hee hee -

T.W.R

23rd October 2005, 21:11

mmm lookin good, what years the bike? its got white face clocks,is it the anniversary model?
hairsprays the trick just watch out in the rain ( has a habit of doin the slippy thing)

Badcat

24th October 2005, 05:51

mmm lookin good, what years the bike? its got white face clocks,is it the anniversary model?
hairsprays the trick just watch out in the rain ( has a habit of doin the slippy thing)

it's a 94, peter doak from emoto got it for me in japan. it's only done 11000 ks.
i think it i s the 25 year anniversary - it has the drum front brake also..
k

Alan

25th October 2005, 08:05

Wow, things seem to be coming along nicely. Really wanna see this when it's finished!
Pictures look great.

sven

29th October 2005, 23:07

... but want to build something very minimalist, with much lower suspension, something with dirt ergos, and a nice timeless retro look.
so starting with a good chassis, modernising it with a better front end with a big disc...

Hi badcat!

Something like this?
http://www.thumperpage.com/pix/08272005/05xtli.jpg
(Hmm, how can I make the pic appear and not just the link?)

Regards
Sven

Badcat

29th October 2005, 23:56

Hi badcat!

Something like this?
http://www.thumperpage.com/pix/08272005/05xtli.jpg
(Hmm, how can I make the pic appear and not just the link?)

Regards
Sven
yes - kind of - but road legal.
thanks for your reply on thumperpage too.
is thye bike yours?
it's a beauty!
ken

Badcat

30th October 2005, 05:59

well, i've sold the vanvan (sniff) and am now commuting every day on the SR.
the motor seems to have developed a serious bottom end knock - so much for the good motor...
seems this donor bike has degenerated into a $5000 rego plate...
oh well, can't do much about that now.
i do have the ex-race sr600 monster motor that i'm told has hardly been run since rebuild, so will poss run the big motor sooned than i expected.
i had planned to do all the suspension, wheels and running gear, get the bike to a point that i was really happy with, and then upgrade the motor at the end.
i also have the rebuilt XT500 motor, and the other option is to transplant the 12v electrics and CDI from the donor SR motor onto the known good XT motor.
It looks like the RGV chassis second bike is not gonna happen due to lack of funds though, so if anyone wants to buy a good RGV 250 rolling chassis very nicely set up for a XT500 / sr500 motor - PM me before i list it all on trademe. i had recently bought a rolling chassis of the same rgv - J so i could start. it has:
wheels
brakes (only one front caliper)
clip ons
tank
seat plastics
would be a good start for a race bike
i have 3 RGV frames - so could do the chassis standard also.
would be a fun project - but just can't afford both now....

k

Badcat

30th October 2005, 06:05

the SR is off to steve bridge at F1 engineering to start the suspension mods this week!
and the tank, seat unit and side covers are at reflections for paint.
i'm going for blood orange and black, in the old school racing style.
it's going to look great!
after that, it's off to peter at custom chambers to build a new header for the white bros e-series muffler.
then - i'll sort the motor, install the new FCR and get it on the dyno.
i'll probably use brett roberts to get it all sorted.
hopefully it will be ready for xmas!

inlinefour

30th October 2005, 11:01

Good choice of single there. Will be a great bike to ride.

Badcat

31st October 2005, 19:44

the second bike (rgv chassis) isn't gonna happen.
so it's up on trademe - without the motor of course.
here's the link...

http://www.trademe.co.nz/structure/auction_detail.asp?id=39419227&ed=true

i have an RGV rolling chassis that i was going to use - will list that soon too.
ahh well, will give me some cash for the ohlins....

k

inlinefour

2nd November 2005, 14:01

Had one of these when I was a boy, great bikes :first:

Badcat

5th November 2005, 06:28

well - the bike's in hamilton with steve bridge for the shortening of the USD front end, fitting the new black spoke wheels, the TT500 swingarm etc.
the spare tank was pretty crap - so dave at reflections wanted the tank on the bike to paint instead. so steve's sending dave the tank, and i guess the painted seat, tank and sidecovers should be a another 2 weeks.
hopefully the suspension work will be done at the same time.
still trying to figure out a front guard.
the MX USD forks have to provision for a low (as in moves with the front wheel) guard, which is really what i wanted.
i may have to run a high front guard - my options are an acerbis supermoto guard - or cutting down an MX guard (to freestyle like dimensions).
hmmmm......

oh, has anyone dealt with shaun harris at moto dynamics?
he has hot prices on ohlins shocks, and as robert taylor has not returned the 2 calls and 2 emails i've sent, he can play "hide and go fuck yourself" as far as i'm concerned.

K

Badcat

18th November 2005, 13:41

well - i picked up the seat, tank, and sidecovers from reflections this afternoon.
the pics below don't do the paintwork justice.
it looks INCREDIBLE.
was expensive, but worth it, as it's exactly how i wanted it.
also - steve from F1 called today and he's started on the front end fabrication!
the USD front end will also now be anodized black....

W00T!!!!

Eurodave

18th November 2005, 14:07

MMMMmmmmmmmm........ very tasty!! gunna look a million bucks when its done!!!

Badcat

18th November 2005, 14:12

DUDE - tail section you made me is now so pretty!
i had them paint the tail light area and number plate mount black, and it makes the lines at the rear so much cleaner.
i'm using buell indicators - tucked right in at the rear.
hopefully the bike will be back in auckland running for my birthday on dec. 5

i'm wrapt.

K

Eurodave

18th November 2005, 14:16

My pleasure sir,:banana:
cant wait for the pix of it all finished & shiny:2thumbsup

Devil

18th November 2005, 14:16

Lookin good!:yes:

Badcat

18th November 2005, 14:20

My pleasure sir,:banana:
cant wait for the pix of it all finished & shiny:2thumbsup

how's yours going?
any later pics?

k

Eurodave

18th November 2005, 14:24

how's yours going?
any later pics?

k

The one on my public profile was the latest one B4 we went to The Gold Coast for a 6 day break last week, back to reality with a thud last night:doh:

skelstar

18th November 2005, 14:37

Wow, that tail-section is great. Edave: did you make it from another or did you just design it and fabricated it from scratch?

Excellent colour choice BTW Bcat.:)

Eurodave

18th November 2005, 14:47

Wow, that tail-section is great. Edave: did you make it from another or did you just design it and fabricated it from scratch?

I made a mold from an original Harley XR750 unit, made a figlass copy of that & in turn widened/shortened/remolded that to suit an old Triumph 650, the bonus is that its just about perfect for Yamahas XT/TT/SR 400 & 500's:yes:

SixPackBack

22nd November 2005, 06:58

When Flat trackers go bad!

Badcat

22nd November 2005, 09:08

When Flat trackers go bad!

that's nasty.

ewwwww

Badcat

22nd November 2005, 09:14

hey all.
i visited the bike at F1 engineering yesterday, and took the painted tank, sidecovers and seat unit down at the same time for brackets etc.
the YZ USD forks are in bits on the bench, so it's all go!
steve reckons it will be finished by mid-december - i hope to have it back for my christmas holiday!
it's tough without a bike - especially as i now commute an hour each way, instead of 20 mins each way on the bike - but i hated riding it with the skinny wheels and awful shocks, so i'll just have to wait.
steve is also going to anodize the fork uppers black and polish the MX triple clamps, so they will look great with the new black rims!!!
woohoo!

bluefish

22nd November 2005, 12:22

Hey there , your project is looking great. I have just got a sr500 anniversary (1983 / 14000km) I just picked it up last night. I am planning to change it into café racer, similar to the images you have (just found your thread have been researching the project for a month or so now). But bloody hell it was a scary ride home, this is the first time I have owned / ridden a bike of this vintage. Jesus I though it was going to spit me off and any moment, it didn’t help that it was pissing down with rain and with old tyres. I was thinking to myself what have I done.

So with the wealth of knowledge that you have what and if you don’t mind can you give me some advice on the best options for the front forks. I don’t know which would be best, recondition them or fit forks from a later bike (as the are so soft). If I go down that track of new front end what’s involved, are there forks that would fit the triple clamps or do I have to basically build the whole front end up from scratch.

Any help would be greatly appreciated.

Badcat

22nd November 2005, 12:38

around $2850?
it was a steal if you did.
they are scary as all hell standard, i rode mine for 2 weeks - and it was awful.
i'm used to modern bikes, cagiva, ducati, KTM etc, and the sr500 is so a 30 year old bike - no matter when they were made as they changed them so little.
PM me for my phone number - i've learned a LOT on the last 6 months and may be able to help with some bits, links, contacts etc.

ken

skelstar

22nd November 2005, 13:13

Hey there , your project is looking great. I have just got a sr500 anniversary (1983 / 14000km)...
Welcome to the site bluefish :niceone:

bluefish

24th November 2005, 17:04

Badcat

17th December 2005, 06:04

I spoke to steve at F1 yesterday.
progress on the bike has been slow, and it's not going to be ready until january.
aside from my obvious disappointment (it's been in hamilton for 6 weeks now), a little more time to consider has given me time to slightly change some things while it's been away and do now some things that i thought i might do later.
so, here's the status:
seat unit is being mounted this week after some changes to the frame.
the aluminium swingarm is on the bike with new OEM bearings.
the front end is cut down and the fork outer tubes are away getting anodised black.
the YZ triples are away being polished.
i've decided to not install the SR intruments onto the YZ triples, as they are huge and heavy. i want a very simple look so and going to get steve to make some mounts for just the headlight and run a digital speedo, like a panoram. this will also get rid of the speedo calibration problem i'll have with a different sized front wheel as with the panoram you simply feed in the circumference of the new wheel and it's done.
it will also eliminate the traditional speedo and tach cable (sr has a mechanical tach). i will end up with the panoram and a digital tach in the long run.
i'm also moving the ingnition key switch off the triples to under the tank.
so that should tidy and modernise the front end a lot.
so that's it really - hopefully i'll get the bike back with all the suspension work and the new wheels and brakes sorted mid january..

here's hoping....

k

Badcat

26th December 2005, 07:09

well - not much to report , but i scored a pair of adjustable konis on tardme a couple of days back, so that saves me buying ohlins (i hope).
hopefully get the bike back in jan.....

HenryDorsetCase

3rd January 2006, 21:53

Badcat

3rd January 2006, 22:36

Ive really enjoyed this thread because I am about to bid on an XS650 on tardme.

I have in mind a hardtail bobber with springer front end (or cut down dirtbike... that was an excellent idea BTW) (at this stage... its all very vague...) sort of like a lot of old Triumph and BSA choppers were done like in the 70's .

I realise that isnt your cup of tea probably but I have really enjoyed following the story of your trials and tribulations....

keep it coming, Im looking forward to the punchline... i.e. when its up and running.

Cheer:)

is it the blue and silver one in otago?
that looks pretty nice.
i want to do a twin next - but will do a more modern motor perhaps - maybe TRX850 yamaha.

as for the XS, take a lool here:
http://www.650motorcycles.com/xs650links.html
loads of inspiration.
and if you have any questions - PM me, i've learned shitloads.

k

Marley

19th January 2006, 08:34

Badcat

19th January 2006, 10:04

Looks like a great thing to do. I'm looking forward to seeing the finished bike.

I was wondering, when you're planning a bike like this, do you work out all the angles like rake, trail, etc. first, or can you assume that it'll work ok since it's based on existing standard frame parts?

Is there any guarantee that it won't handle like crap?

Also, do you do the wiring yourself?

no - F1 engineering are adjusting the suspension length to ensure the geometry is all good.
there's little wiring needed actually - as i'm using a late model donor.

ken

SixPackBack

19th January 2006, 10:05

no - F1 engineering are adjusting the suspension length to ensure the geometry is all good.
there's little wiring needed actually - as i'm using a late model donor.

ken

Must be nearly finished now Ken, how about some photos:niceone:

**R1**

19th January 2006, 13:48

Badcat

19th January 2006, 13:59

Man, i just read all 5 pages of this interesting thread stopping my self from going to the last page to have a look at the completed bike and found it's not FINNISHED!!!:angry2: hurry up man...

but seriously looks like a fun idea, wouldnt mind another project....

yep - still waiting for F1 to complete the suspension work....
as soon as it's back - there'll be plenty of pics i promise.
and if you think YOU want to see it complete - think how it must be for me....

k

Badcat

19th January 2006, 18:20

just spoke to F1 engineering.
front end is shortened, anodised and triple clamps modified to fit the SR frame new steering stops made and all good. front end is on the bike!
the rear subframe is shortened and the seat unit is on and solid.
now it down to fitting the new wheels and the disc brake master cylinder and pedal fabrication, sprocket and chain.
they are also moving the ignition key switch to below the tank, and fitting the new Koni rear shocks and the white bros CRF 450 exhaust and either re-bending the stainless header or making a new one (after i deliver the parts next week that is)
it looks like it's 2-3 weeks away now.
lots of progress!

k

Badcat

24th January 2006, 15:06

well - i dropped off the final parts this morning - the konis and exhaust - some chain tensioners etc.
the bike looks INCREDIBLE, and is about 1-2 weeks away now..
steve still has to fabricate the rear brake master cylinder mounts, mountg and align the rear wheel, and modify the rear caliper mount.
also now the exhaust header and the new white bros exhaust.
also sprockets and chain etc, and new banjo bolts with brake light switches.
then it's details and the bike is ready.
we decided to keep the original clocks and headlight for the moment, as it was easier to remountg these than to screw around.

pics attached...

Badcat

24th January 2006, 15:10

oh, and most of the parts are just sat on the bike for the pics.
and the shocks in the pics aren't the ones i'm using.

the think that really shocks me is how much shorter it is, and the forks are a matt black anodise, they look bad ass.

i have to find a front guard now - i may use an acerbis supermoto one yet, need to see what it looks like.

oh, and it looks all wrong on the suspension, as it's on the centre stand.

Badcat

24th January 2006, 15:14

hee hee......

Eurodave

24th January 2006, 16:59

Yeah baby, yeah, lookin good Badcat!:niceone: Wotcha gunna do for the exhaust?

nudemetalz

24th January 2006, 17:15

Damn !!!!! That looks awesome, Badcat !!

2_SL0

24th January 2006, 19:07

Thats looks primo :2thumbsup

ducatilover

24th January 2006, 21:05

pharque! i love it:woohoo: :ride: thats a real nice toy:clap: go hard dude

Badcat

25th January 2006, 06:46

Yeah baby, yeah, lookin good Badcat!:niceone: Wotcha gunna do for the exhaust?

thanks Eurodave.
i have a large diam. stainless pipe from the RGV/SR race bike i bought, and i'm using that pipe with a new white bros E-series oval canister (originally for a CRF 450) kicked up at the back like a sportsbike.
i was going to go the chrome reverse meg old school way, but want the bike to have a "hybrid" old/new look.

k

SixPackBack

25th January 2006, 07:11

Looks cool K :first: ......whats the tail/ seat from?

Badcat

25th January 2006, 07:51

Looks cool K :first: ......whats the tail/ seat from?

it's a modified replica of the harley XR750 flat track seat.
Eurodave made it for me. it'll be on the road in a couple of weeks!

woohoo!!

nudemetalz

25th January 2006, 08:06

Did you ever consider doing an XR750-style exhaust ?
(ie along the side of the bike)

Badcat

25th January 2006, 08:34

Did you ever consider doing an XR750-style exhaust ?
(ie along the side of the bike)
yep - i did actually mock one up but i thought it made the bike look like a fake harley.
i want the bike to be something different, a mix of old and new - that's why i've used Upside down forks and pro-taper bars etc. the sportsbike style exhaust looks killer - trust me.

K

nudemetalz

25th January 2006, 09:54

Fair comment, good on you for being different.

Can't wait to see them finished article, looks awesome so far.

ducatilover

25th January 2006, 10:02

i'd like to do something like that...:yes: i just dont have the skills [yet]:angry:

zeRax

25th January 2006, 10:05

god thats nice, bet i cream when i see it complete, damn thats nice..

Badcat

19th February 2006, 11:46

well - steve called last night.
bike is almost complete - i'll prob pick it up midweek.
i still need to have an exhaust made and a changuard.
and find a front guard
anyone good at making chainguards?
i'd like a carbon fibre one if poss...
anyway - looks like it will be FINALLY on the road in a couple of weeks!!!
pics to come when i get it home!

K

Badcat

19th February 2006, 12:06

oh, and i won't be doing the modern exhaust now.
i'm going the old-school reverse meg high-pipe way after all.
kinda like this....
hopefully custom chambers can do it - i'm thinking of black istead of chrome too...

ducatilover

20th February 2006, 08:29

nice:tugger: my bros650 now has a reverse megaphone shorty:Punk: and it is soooooooooooooooooooooooooooooooooo beautiful sounding, it just looks fucked up:blank:

Owl Morris

21st February 2006, 02:09

Hey BadCat

A pics of the sr500, before and after I got it.
It had bars, stock indicators, and big ugly mirrors and shocking old tyres

So I got some clipons, small indicators, and a bar end mirror and got bridgestone bt45 tyres.
So it looks alot better now, Now its now running properly, bogs down when you give it full throttle,
yeah for old bikes
Make it breathe. Take off the standard carb and throw it as far as you can then take off the muffler but don't throw it, you will wreck your back,they weigh a ton. The carb should be 36mm or bigger(bigger will need a new manifold). A new pipe and a 3ft. diameter megaphone, your neighbours will shower you with gifts every time you come home.:Oi:
Here's one for SR or TT owners next time you split the cases' put a fresh gasket under the oil pump backing plate, even though the books say not to bother unless you have to. Mine popped a corner out and George W'ed my piston and rockers.:thud:

Badcat

25th February 2006, 00:36

hey.
picked it up today.
still needs an exhaust and a chain guige and a front brake.

pic below.

woohoo!

Badcat

25th February 2006, 00:40

hee hee - with daddy...

Bonez

25th February 2006, 12:50

hee hee - with daddy...Ya look like a happy wee lad ;).

Badcat

25th February 2006, 14:57

Ya look like a happy wee lad ;).
\
yep - i'll be happier when it's on the road - hopefully a week!!!!
k

ducatilover

26th February 2006, 20:07

thats amazing dude! im lovin it:apint:

Badcat

4th March 2006, 19:58

well, i got it home from custom chambers (sweet pipe peter...)
i dropped it down to kerry aqt motohaus to straighten out a couple of things and bleed the front brake etc.
i picked up the black acerbis front guard and fitted it this afternoon, just need to wire up the rear indicators and tail light.
i do have a problem though - the right indicator lamp stays on no matter what..
anyone have an idea or maybe can help?
here's some pics...

NordieBoy

4th March 2006, 20:12

Ohhhh baby!

:apint: :corn:

Sensei

4th March 2006, 20:20

Badcat

4th March 2006, 20:26

From owning 4 TT/XT 500's the wiring is abit funny brown is used as an earth on some models as well as the black so just check that out . I think a guard on the front wheel would look more the Style that you have gone for rather than the High one but thats just me . Sweet bike . :rockon:

yeah, the guard is temporary - I plan to change the guard for a wheel-fitted one, but the shortened MX forks have no mounts. i'm working on a plan to make brackets off the front axle mounts. The supermoto guard looks better than i was expecting, but doesn't really go with the rest of it.
but - it's been away for 4 months and i need to RIDE the damn thing.
ther's heaps i'll refine and change, but i want to get it moving while there's still some good weather...

K

DEATH_INC.

5th March 2006, 18:22

Lookin good man! Well done. :niceone:

ducatilover

5th March 2006, 21:34

...... wow ........ ummm...... yeah.....wow! i love it, as sensei said it would look better [to me] with a lower front gaurd. lovely bike though congrats

riffer

6th March 2006, 07:59

Ken - that's looking really mint.

I thought you were doing the scrambler exhaust thing?

Those wheels look great! And the nice shiny swingarm...

Would you be able to give us a parts list and breakdown of all the work...

It will be interesting to see how you go with certification/VINning it.

Well done mate. I hope it's been worth the wait. You look happy.

Badcat

6th March 2006, 08:03

thanks simon.
the high exhaust just didn't work on the end - it either would stick out and burn my leg, or melt the sidecover.
the exhaust we made in the end is a better fit to the bike in my opinion, and the pic doesn't do it justice.
the bike is still nowhere near finshed, and i will so a summary including a parts list soon.
certification is something i'm going to start soon.
Ken

Badcat

29th April 2006, 09:48

Hey all.
after finally getting the front end rebuilt (thanks matt at mt eden motorcycles), the bike is now capable of a decent punt through the twisties!
i took it for it's first decent ride, up the piha road.
finally - the bike is starting to WORK.
the front end is sweet, the awful tight off camber rutted corners were no problem. the front actually feels as good if not BETTER than my KTM with it's WP suspension !!
the rears are not as good. i got some used konis as the ohlins became a dream due to the fabrication budget blow-out. the konis are oversprung and underdamped. not good - and so apparengt now the front is working well
so.......
i've been chasing a pair of ohlins on ebay for the last 4 months, and last week the vendor accepted my offer.
new they were $1800 from robert taylor (not that he ever answered my 3 emails ot my 2 phone messages) and shaun here on the list offered them to me at a brilliant price - much better than robert, my budget just couldn't get there.
i finally got the ohlins for $750 inc freight - so they are on their way.
next steps are to tidy up the headlight and instuments, i want to lose the heavy chrome insruments and go with a bike speedo or panoram.
when i do that however, the headlight will loook like it's hanging in the breeze, so i will have to remount it closer and tidier.
i have a ducati monster s4 bracket that i'll be modifying to tuck the headlight in and i'm hoping to move the ignition keyswitch to under the tank.
i'd go to an enduro headlight, but it would ruin the oldschool look.
so that's the plan, and loose that awful supermoto front guard.
what i really need is an engineer to make some brackets etc..
any volunteers?

K

ducatilover

29th April 2006, 11:03

good shit man. i want ohlins for my silly gutless spada:rockon:

Badcat

29th April 2006, 11:19

wow.
just realised this project has been a year so far, and the bike is freally only properly rideable now.
funny thing is that the first real ride was on the 24th april - a year TO THE DAY from the first post ..

spooky.

still - it's all been worth it to see my idea on the road in the flesh.

k

XTC

29th April 2006, 13:04

Looking great..... Only a year eh? I've had a honda QA50 waiting for assembly for 10 years now..... Maybe I should pull it out of the attic and make a start.

Badcat

6th May 2006, 21:17

MY OHLINS ARRIVED!!!

well - the Ohlins rear shocks arrived a couple of days ago, and i fitted them (well - actually Kerry at motohaus helped as the spacers needed turning down to fit).
I met Postie and Cibby Chick today at Motohaus too - nice to put faces to the names.
Anyway - back to my new Ohlins....

THEY ARE INCREDIBLE.

The really stunning thing is how much smoother the bike is now to ride!
i suppose the "roughness" of a non-balance shafted single is transmitted via the swingarm and the rear shocks do actually dampen that vibration and roughness.
Well - believe it not the new ohlins make the bike feel a lot less rough and much more civilised and comfortable.
i've only ridden the bike home from motohaus, so i'll take it for a decent ride tomorrow, and see if the hadling is as much better as i think it's going to be.

they look totally horndog too.

The new shocks are 10mm longer and hopefully they will help the bike steer a little sharper without affecting stability.

so - thatnks for listening.

WOOHOO!

skelstar

8th May 2006, 09:34

Awesome dude. Obligatory pictures soon I hope. Look forward to seeing the bike in the flesh someday but not sure how thats gonna work :).

Badcat

26th May 2006, 23:14

well - after ditching the speedo anmd rev counter i have hooked up an LCD cycle computer.
if anyone's interested i could write up the process with a shopping list.
cost about $120 all up .
k

spudchucka

27th May 2006, 08:40

well - after ditching the speedo anmd rev counter i have hooked up an LCD cycle computer.
if anyone's interested i could write up the process with a shopping list.
cost about $120 all up .
k
I'm going to need something like that when I motard the XR, so yes please, write it up if you don't mind.

Badcat

27th May 2006, 10:46

okay - so i wanted to remove the heavy bulky old instruments to get the bar area as simple and light as poss. Also the speedo calibration was going to be way out as the bike had an 18" front wheel originally and the new front end/hub had a speedo drive for a 21" wheel.
so - i originally looked at a trailtech panoram:
http://www.dirtbike.co.nz/images/products/Endurance_Computer.jpg
but no-one in auckland had one in stock so i did some research and found that they are only really a cycle computer anyway.
i found a very compact and light unit from CATEYE called and Enduro 8.
http://www.cateye.com/en/products/viewProduct.php?modelId=5&catId=6&subCatId=0
it was $60 from a local bike shop (cyco in ponsonby).
of course the standard wire was too short - so i also got the extended cable
Cateye call this the Bracket sensor kit - (long) P/N 169-6565N
also, cycle sensor magnets are useless as you can't get them close enough to the sensor (spokes are too far away for the 5mm range of the sensor)
so i bought the panoram disc rotor bolt with build in magnet:
near the bottom of this page - http://www.dirtbike.co.nz/default.asp?pageid=12#
mounting the sensor on the fork tube (my bike has USD forks) was easy once i had the disc bolt and i simply ran the cable up the brake line to the handlebar area.

i'll post some pics and comments on using the unit later today.
any queries - PM me.

K

XTC

27th May 2006, 11:49

The only problem I had using a cycle comp on the bike was that I couldn't see it at night. Has yours got a light or something?
Andy.

Badcat

27th May 2006, 12:44

no - it's not illuminated and that's its only drawback.
i'm trying to find an other cateye model with a light - that takes the same cradle.
will post my findings...
k

sAsLEX

27th May 2006, 13:23

A little black hood with a LED would be a simple way to light it only need a resistor and a LED hooked in to the Lighting loom!?

Badcat

27th May 2006, 13:35

A little black hood with a LED would be a simple way to light it only need a resistor and a LED hooked in to the Lighting loom!?

maybe even I could make that.
any idea what value LED and resistor i'd need?

Badcat

27th May 2006, 14:29

here's the computer on the bike.
now i need to tidy up the gap where the instruments were and make some new brackets for the headlight.
i wangt to move the ignition ket to under the tank also to simplify the handlebar area.
also a pic of the sensor - you can't see the magnet bolt but it's in place of tone of the disc fasteners.

XTC

27th May 2006, 14:32

Looking Good! You could alwats get one of these for Illumination :)
http://www.trademe.co.nz/Sports/Cycling/Parts-accessories/Lights/auction-57926405.htm

sAsLEX

27th May 2006, 15:12

maybe even I could make that.
any idea what value LED and resistor i'd need?

http://www.jaycar.co.nz/productView.asp?ID=ZD0169&CATID=33&keywords=&SPECIAL=&form=CAT&ProdCodeOnly=&Keyword1=&Keyword2=&pageNumber=&priceMin=&priceMax=&SUBCATID=573

any would do depending on the colour and size you were after, but you need to restrict the current through it to avoid burning out.

See that one has a forward voltage of 2 which means 2 volts will drop across emitting light and the other 10-13 will have to be dissapated by the Resistor.

As V=I*R, and the current you want through the LED is 30mA (from their datasheet) 13/30*10^-3 = 433

now since you cant get all values of resitor just pick one thats close.

Most DSE geeks should now what your after if you go in and ask.

Or you could go a bit crazy and copy this http://saslex.orcon.net.nz/LED_DRIVE.JPG

Badcat

27th May 2006, 15:23

Or you could go a bit crazy and copy this http://saslex.orcon.net.nz/LED_DRIVE.JPG

what is THAT?

XTC

27th May 2006, 15:38

So are you coming on the ride?

sAsLEX

27th May 2006, 17:17

what is THAT?

LED brake light basically.

spudchucka

29th May 2006, 09:18

well - after ditching the speedo anmd rev counter i have hooked up an LCD cycle computer.
if anyone's interested i could write up the process with a shopping list.
cost about $120 all up .
k
I found this while browsing:

http://www.motostrano-store.com/trtetrco.html

It's back lit so will be OK for night riding.

Badcat

29th May 2006, 09:23

man - i'd buy the trailtech then.
dirtbike.co.nz has them:
http://www.dirtbike.co.nz/default.asp?pageid=12
$179 and they do one specifically for the XR650.
easy!

k

skelstar

29th May 2006, 09:32

Thats a pretty sweet little unit. Very cool.

spudchucka

2nd June 2006, 14:31

Badcat,

I found this and thought you might like a look.

http://www.4strokes.com/articles/honda/flatrack/

Badcat

2nd June 2006, 14:34

Badcat,

I found this and thought you might like a look.

http://www.4strokes.com/articles/honda/flatrack/

WOW.
that is NICE.
i'm looking for my next project......

Badcat

14th May 2008, 16:46

well - after my buell was stolen, i'm getting the SR sorted.
i'm planning:
rear brake upgrade
front brake upgrade (floating 310 disc and 4 pot caliper and matching master cylinder)
harley sportster style front guard/fender (have to make up brackets due to MX front end)
put standard instruments back on
make a chain guide
shorten handlebars

so will update this thread as i go.

thanks for listening.
ken