Flat Track Replica xt500 project

**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/a...sp?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/defau...ject=Dan%20650

http://atsearch.autotrader.co.uk/WWW...geId=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

Originally Posted by Motu

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.

thanks motu.
i found owl's profile and have PMed him.
looks like he's not online much.
i'll probably post me progress as i go with pics etc.
kind regards
ken

**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

Originally Posted by Eurodave

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

**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/a...sp?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