TT500 restoration project

**Wired1** · 13th July 2008, 11:22

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** · 13th July 2008, 12:16

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

ken

**dino3310** · 13th July 2008, 12:55

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

**Badcat** · 13th July 2008, 13:07

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** · 13th July 2008, 13:12

mybad

**Wired1** · 13th July 2008, 15:34

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/List...613443&ed=true

**dino3310** · 13th July 2008, 15:44

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** · 15th July 2008, 19:16

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** · 15th July 2008, 20:29

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/my...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** · 17th July 2008, 14:57

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** · 16th November 2008, 18:54

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/sh....php?p=1812348

**cave weta** · 17th November 2008, 07:04

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** · 17th November 2008, 07:09

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