TT500 restoration project

[Wired1]

I've just bought a 1980 TT500 in a sad state with the intention of restoring it and eventually racing it in the VMX. I have probably paid a little too much for it but I have been looking for some time and there just aren't any out there for what I paid for this or that need restoring.
The 1980 has all the good stuff like the alloy swingarm, improved front rake (well it looks cooler), as well as the old favourites like the alloy tank and that awesome sounding motor.
I am still finishing a couple of other projects so this one will take at least a year to complete, maybe longer. First I need to finish my second TT250 and put the XT550 back together so I've got something to ride - plus I desperately need the bench space!
Anyway, the before photos are below and here is a short list of the most obvious parts I need:
- 2 x rear shocks (I think the wooden monoshock is going to be a bit hard)
- seat foam or spare seat,
- exhaust pipe, even a crappy one to copy would be good,
- workshop manual!
- spare set of wheels (for road tyres?)

[Squiggles]

- 2 x rear shocks (I think the wooden monoshock is going to be a bit hard)

Yer, get adjustable bamboo jobs :)

[Wheeliemonsta]

I've just bought a 1980 TT500 in a sad state with the intention of restoring it and eventually racing it in the VMX. I have probably paid a little too much for it but I have been looking for some time and there just aren't any out there for what I paid for this or that need restoring.
The 1980 has all the good stuff like the alloy swingarm, improved front rake (well it looks cooler), as well as the old favourites like the alloy tank and that awesome sounding motor.
I am still finishing a couple of other projects so this one will take at least a year to complete, maybe longer. First I need to finish my second TT250 and put the XT550 back together so I've got something to ride - plus I desperately need the bench space!
Anyway, the before photos are below and here is a short list of the most obvious parts I need:
- 2 x rear shocks (I think the wooden monoshock is going to be a bit hard)
- seat foam or spare seat,
- exhaust pipe, even a crappy one to copy would be good,
- workshop manual!
- spare set of wheels (for road tyres?)

Gidday Wired1,
Another Ahberg Replica on it's way, is it...?

Good luck with the project, it please's me no end every time I see an older bike about to come back from the grave

Several million points out of ten for style and execution...

Cheers

:rockon:

[bimotabob]

Hi,

I know a guy with a mint TT500 he has had from new!
Still on the road and has all the hot up parts that used to be available for them like triple clamps etc.
Awesome machines, good luck with that!

Cheers

[Wired1]

Yeah they sure clean up good. I spotted a restored one in one of the VMX magazines (just looked and can;t find it now of course!) anyway it was a poor man's HL500, had a silver frame and bead blasted engine, looked real sweet. I'm not sure where this one will end up but I will be going for the mint-but-ridden look.

[Badcat]

I've just bought a 1980 TT500 in a sad state with the intention of restoring it and eventually racing it in the VMX.
The 1980 has all the good stuff like the alloy swingarm, improved front rake
that isn't the original front end - is it?
i have loads of motor bits if you need - including a newly bored unused still wrapped barrel - wiseco pison - reconditioned head etc.
let me know if i can help - the bike will be GREAT!

ken

[Turtle]

Great to see these bein restored and even better sein them on the road...I have the yellow tanked TT (needs resto) and 77 XT (2/3 done).
Shocks are available aftermarket via northern accesories and musket muflers will do you a front pipe.I have several diferent manuals etc.....let me know if you would like anything photo coppied.

[Wired1]

that isn't the original front end - is it?
I think it's original - anyone know better?

[Wired1]

Update: New clutch and decompression cables, modified new throttle cables, better handlebars, elcheapo rear shocks, tank polished, new front brake shoes, rebuilt front hub and brake, rebuilt rear brake linkages and repaired foot brake, replaced foot pegs with newer ones, made a seat foam and recovered the seat, stripped side covers and repainted to match plastics.
This is of course the original colours used in 1980 (not), well the fenders were such a nice shade of blue and I picked up the front and back for $40 off trademe so I thought WTF, let's go blue.
Replaced the front forks with TT250 ones with air valves I had lying around waiting for a project. They are basically the same 36mm forks used on both bike but without the indent at the top, and the TT250 ones are 25mm longer.
I am hoping to get a set of 1983 RM250 forks this weekend which are something like 44mm and have been used on similar projects by others so the plan is to customise them to fit the TT. The 83 RM was the last drum brake front end so I should still be OK for the VMX racing.

[Wired1]

Well I've finally got the TT500 going again, well good enough to be riding. I got a bit side-tracked with a TT250 and an XT550. I ended up taking the blue plastics off this and put them on the XT550 so this is now white like it should have been. I put the disks back in the supertrapp that I had borrowed to get my SR400 through compliance, used the rear knobbly off the SR400 (yes really). New points, condenser, new chain & sprockets, cleaned out the carb, pulled the clutch out and freed it all up, new throttle cables, roughly timed it and off we go. It starts reliably on about the third kick now, and doesn't carbon up the plug so I must have got something right.
I've run out of time to take her out this weekend but I took it up the road for a blast and it's a little light in the front on the first three gears, and all the rest of them are there where they should be too. I need to time it better but I need to get a timing light first, one that doesn't need a 12 volt supply!
At least now I have something to ride while I'm working on the SR400.

[Wired1]

Has anyone done a 12 volt CDI conversion on a TT500 engine? I have just been through all the timing stuff, new points, timing light etc on the mighty TT and it is running sweet but I can;t help thinking how much easier it is on the SR500 - the original plug & play.
The TT500 has the extra gear drive thing in the right hand cover for the points but you could just blank it off or even just remove the points plate. It would have a different setup in the magneto side, different coils and some sort of pickup arranagement. I will eventually get both motors apart but I'm wondering what parts I should be keeping an eye out for.
Any thoughts?

[Pedrostt500]

DROOOOOOOOOOOOOOOOOLLL
You have made a nice job of it, From memory there were two coils, a ligting coil and the magnito coil, as for after market CDI the only ones I can remember were one off specials made by an electronics Geek.

[Badcat]

Has anyone done a 12 volt CDI conversion on a TT500 engine? I have just been through all the timing stuff, new points, timing light etc on the mighty TT and it is running sweet but I can;t help thinking how much easier it is on the SR500 - the original plug & play.
The TT500 has the extra gear drive thing in the right hand cover for the points but you could just blank it off or even just remove the points plate. It would have a different setup in the magneto side, different coils and some sort of pickup arranagement. I will eventually get both motors apart but I'm wondering what parts I should be keeping an eye out for.
Any thoughts?

hey.
i ended up getting an sr500 - but looked into this a lot on my project 500
there's an australian company doing a kit but it's over $1000.
the cheaper way would be transplanting the electrics/CDI and sidecover from an SR500 - but thise parts are hard to find as most xt/tt500 builders have the same idea.
have you tried calling NZ wreckers?

some links:
http://www.thumpertalk.com/forum/archive/index.php/t-244757.html

http://www.norbsa02.freeuk.com/goffyelectrex.htm

http://www.eurospares.com/tt500.htm

ken

[Wired1]

Thanks for those links, the first one in particular. I thought the fly wheel covers would be the same but apparently not. I've got both bikes and I'v got the SR400 motor on the bench at the moment so I might whip the covers off and do a comparison. The basic bits I would need would be the SR500 alternator with the CDI pickup and base plate, the flywheel, CDI unit, 12 volt coil and fly wheel cover. I have a couple of spare XV750 coils so they will work for the coil so I'll save some searches on Trademe and Fleabay and see if I get lucky. Like you say though, everyone else with an early model XT or TT is probably looking for the same bits! :banana:

[Badcat]

yep - sounds about right.
as to the cdi - there was a guy on trademe making them - he was based on the north shore - and used to advertise on ebay aus too.
if i can find any info - i will forward it.

k

[Wired1]

I had a go a making an aluminium side cover this week. I used 2mm sheet alloy and got a piece big enough to make maybe 4 of them. I used the worst end of the sheet for the first one as I figure I may stuff it up but it actually worked out prett well. I made a cardboard template from the old plastic one for both sides but I think I can come up wit a design that will fit either side with a few very minor tweaks. I could use a roller and a bender as this was all done with the vice and over my knee but that can wait for the next version. Now I'm thinking about a new skid plate and a rear fender in alloy...

[Badcat]

shit - that's looking good.
you could sell those on ebay ...

ken

[dino3310]

yes there's certianly some money in the restored classic's (if you could part with them).

[Badcat]

i meant the side covers - not the bike...
although - i'm sure the bike will be attractive - i meant there's a lot of people looking for tt500 sidecovers..

[dino3310]

:laugh: mybad

[Wired1]

Lets see if there is a market then, I cut loose today and made a skid plate to match. I made a spare which I have listed on Trademe so if it does alright I might make some more bits.

http://www.trademe.co.nz/Browse/Listing.aspx?id=165613443&ed=true

[dino3310]

very nice, looks good. i jamed my one under a pellet and pulled it up to the required angles to fit, dont look half as good as your properly rolled one but once on the bike she look's the part.

[halo_bone]

Hi everyone,

I have a 1977 tt500 is pretty decent shape--it's starting and running (but have to change spark plug a lot), has a little rust on the exhaust pipe. It's is basically needing some work.

Service manuals: is there any you would recommend?

I have been looking at the Haynes 75-81 500 service manual, the Cycleserv enduro manual written in 76, the Yamaha factory Workshop Manual 76-81, Clymer manuals, and 76-79 500 Yamaha-published Service Manual.

If you have any thoughts on any of these, I would love to get the insight. This will be my first real repair job, tearing apart an engine--so the more detailed and step by step, the better.


Are there any old bike repair forums? This would be a huge resource for me to be able to search and ask questions.

[Wired1]

Hi Halo, I've got the Haynes TT500 manual and it seems to cover the essentials well enough. I haven't had this engine apart yet so I guess the real test will be how well it shows and describes the reassembly process. There are others on this site who will answer that question better than I. I have recently overhauled a later XT550 motor following the appropriate workshop manual and discovered several very serious mistakes - like critical assembly stuff left out or in incorrect sequence so as they say, don't belive everything you read. About the most useful stuff around are the Yamaha parts catalogues. They are available online here: http://www.yamaha-motor.com/sport/myyamaha/prompt/L3Nwb3J0L3BhcnRzL2hvbWUuYXNweA==/Parts%20Catalog/starthere.aspx just click the "proceed to parts catalogue" button and you're away. I have the same files in pdf from goodness knows where and I find I am printing these out regularly during dissassembly and reassembly alike.
My TT500 has a similar plug problem in that it is regularly carboning them, probably due to a pod inlet filter and supertrapp exhaust buggering up the mixture. I am planning on having a fiddle with the needle height to see if I can lean it up a notch but I'd be keen to hear if you make any progress in this area too. I'm also wondering if the 6 volt coil is reliable and is actually delivering a large enough spark.
Post some picks of your TT on your profile page, and welcome to KB.

[halo_bone]

Thanks for all the info, it's all helpful. I'll have to watch out for manual mistakes, for sure.

I'll update you on whatever happens with regards to the spark plug problem.

[Wired1]

Well I've run out of enthusiasm for this project, I have the TT250 to finish and that will satisfy my VMX needs, what I really need is a road-registered trail bike like a DRZ400 or XR400...

http://www.kiwibiker.co.nz/forums/showpost.php?p=1812348

[cave weta]

I miss mine!- I sold it to a dude in Invercargill on trade me.
It was about 2.5 years ago- a real tidy yellow one with a spare motor and wheels. does anyone know it?

[cave weta]

I have a 2003 DRZ400 e with Procircuit T4 and full road legal - it hardly gets used. has new front and rear knobblies 3 rides old and a brand new battery.
PMme for photos and price

[Wired1]

Relisted, lets see who wants it for Christmas!
http://www.trademe.co.nz/Browse/Listing.aspx?id=191948455

[dino3310]

nice mate very nice, it would look good in my christmas stocking but im not ready for a divorce :lol:

[Wired1]

What's a DR750? sounds like a slightly oversized DR400? That must be a bitch to kick over!

[dino3310]

What's a DR750? sounds like a slightly oversized DR400? That must be a bitch to kick over!
slightly oversized!:lol:.
she's one of the original dakar superbikes.
electric leg, ooozes torque, shit loads of power, comfy and handles bloody well, quite nimble and easy to move around on the twisties, 29litres of tank gets me 450-500klms, here's some of my pic's http://www.kiwibiker.co.nz/forums/image_browser.php?do=view&pp=40&userid=7575.

[Wired1]

Auction ends Monday 16th at 8:00pm :)