Flat Track Replica xt500 project

**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

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.

**Badcat** · 21st May 2005, 16:58

Originally Posted by Motu

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 .

**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

LB · 30th July 2005, 05:07

.
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Looking forward to following the progress Badcat. Hope to perhaps see it at New Plymouth on 5th November??
.
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**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/a...sp?id=33647325