OzVMX Forum

Marque Remarks => Yamaha => Topic started by: Tooheys on November 07, 2012, 01:30:43 pm

Title: Xt500 street tracker build.
Post by: Tooheys on November 07, 2012, 01:30:43 pm: Hi,

So I recently purchased an XT500 with the original plan to build a HL 500 lookalike. After doing some research I decided it may be easier to build a street tracker (road registered) and maybe build a HL500 later with a GMC frame etc. anyways below is what I started with.
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/6c7f3c26dfcdd25cacd6cb187ca4476b.jpg)

And this is one of the bikes I will be using for inspiration. I found it from a google image search but have since discovered t is owned by sven from the SR500 forum.
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/2125938b17dcf84bfa839d755f541d70.jpg)

So the motor was stuck and the PO told me that it was just because it had been sitting for awhile. Anyways I did a couple of checks and started pulling bits and pieces apart. After some digging i found that there is a problem with what i presume is the selector fork. Still waiting for the workshop manual but I think it is either missing or has broken a spring. Selector flops around and also there is a piece of hose used on the other side for what seems like a spacer. Also there is some damage to the drive ring from the clutch and also the drive gear for the valve train.
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/16ED7B2A-1EC6-4D77-A7E9-F185A359EABF-4861-000002E4617AA880.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/64BF19EB-2FA0-4104-B771-06DB83168D2C-4861-000002E457CD80BB.jpg)

I think this nut coming loose is the source of the problem and the thread is a bit chewed out.

(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/B9EC2009-C1BE-4CA2-9000-C97AF5D50DB8-4861-000002E44E5681C6.jpg)

Have also got some GPX250 forks as i found that they were 36mm so i don't have to stuff around with adapting triples etc. I had a swingarm from an XR600 that I was saving for another project and I found that it fits perfectly. Just needs some shock mounts and some different bushes and i get easy disc brake and 100mm longer swingarm. Below is a bit of a mock up.
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/41B39135-F77B-46A7-B12E-4360504492E0-4861-000002E437CC988D.jpg)

Any comments welcome and if anyone can help with a tt/xt500 alloy tank and maybe sugestions for wheel size, not sure if I should go 18 or19 inch.

Cheers, paul
Title: Re: Xt500 flat tracker build.
Post by: Tooheys on November 07, 2012, 01:34:36 pm: Hmmm typical newb who cant get photos to work :(. Off to the "this is how you post photos newb!" Thread
Title: Re: Xt500 flat tracker build.
Post by: TT5 Matt on November 07, 2012, 02:38:54 pm: looking at your pics you need a new primary drive gear and clutch basket,with your crankshaft tread damage a metric tread file should sort that out a get a new nut for it.with your gearlever shaft you need a washer and circlip on the gearlever side to stop the teeth on the other side from getting out of mesh which it seems to be,id also be checking your input shaft bearing on the gear box for too much end float.there a nice old motor the 500 thumper and theres still plenty of parts around on ebay for them ;)
Title: Re: Xt500 flat tracker build.
Post by: steve234 on November 07, 2012, 02:51:36 pm: Pull the rake in to 25/26 degrees. For wheels depends what you intend to do with it, for racing definitely 19" for road stick with 18". Well that's what I would do.

Can I have the old forks?

Cheers,
Steve
Title: Re: Xt500 flat tracker build.
Post by: firko on November 07, 2012, 03:42:13 pm: Here's a bunch of modded stock framers. As Stevo said, pull the rake in to 25-26 degrees and run 19'' up front with an 18" on the rear with a trials tyre. Running the US style 19" rear and Maxxis tyre would work on an oiled blue groove track but there aren't very many of them left in Oz. The GPX250 forks are a good idea but you might find some scrutineering drama if they aren't built prior to 1978. For club days I don't think anyone whill give a damn. Jim on this forum races a TT500 in an American flat track frame (can't remember which brand) so he might be able to offer some hints.

(http://i1112.photobucket.com/albums/k495/firko2/08Aug03-YamahaTT-4.jpg)
(http://i1112.photobucket.com/albums/k495/firko2/08Aug03-YamahaTT-3.jpg)
(http://i1112.photobucket.com/albums/k495/firko2/08Aug03-YamahaTT-1.jpg)
(http://i1112.photobucket.com/albums/k495/firko2/08Aug03-YamahaTT-2.jpg)
Title: Re: Xt500 flat tracker build.
Post by: Tooheys on November 07, 2012, 05:39:15 pm: Thanks matt. I'm just waiting on the workshop manual before I go pulling it apart too much more but I will check end float etc as I go.

Steve, yeah I did think about the rake. A mate has a guy that can do that so I might have to chase down his number. And yes you can have the forks although you may have to wait till next month to get them. They badly need a rechrome I can take pics if you like. Was actually thinking of offering some of my leftover bits so I'll start a thread in The for sale section.

Firko thanks for the inspiration photos and tyre advise. I should have been more clear though I want this to be a road registered bike, I didnt think about racing it. Maybe once I'm done I should look into the racing on club days.
Title: Re: Xt500 street tracker build.
Post by: pancho on November 07, 2012, 06:29:40 pm: Great project Tooheys!
Re racing on club days-DO IT DO IT DO IT!
Cheers pancho.
Title: Re: Xt500 street tracker build.
Post by: ola_martin on November 07, 2012, 06:39:20 pm: You work on your bikes in a skirt?? :o
;)
Title: Re: Xt500 street tracker build.
Post by: Tooheys on November 07, 2012, 07:00:44 pm: Quote from: ola_martin on November 07, 2012, 06:39:20 pm
You work on your bikes in a skirt?? :o
;)
Haha no they are boardshorts with an unfortunate pattern on them, so they only see the shed nowdays.
Title: Re: Xt500 street tracker build.
Post by: smed on November 07, 2012, 07:06:05 pm: I thought you were in your PJ's & slippers :D
Title: Re: Xt500 street tracker build.
Post by: Iain Cameron on November 07, 2012, 07:42:07 pm: Ive got a Cycleserv TT/XT up to the "F" model I can loan you if you need it . Iain
Title: Re: Xt500 street tracker build.
Post by: Tooheys on November 07, 2012, 07:55:54 pm: Iain,

Its all good mate I have one on order from ebay that should arrive in the next couple of days. I go back to site next tuesday anyway so wont get much done until next month. Thanks for the offer though :)
Title: Re: Xt500 street tracker build.
Post by: jimg1au on November 07, 2012, 09:04:39 pm: mine is all staracer frame seat and tank, i use betor 35mm forks and ossa tipples.
atm 21 front and 18 rear but it might change.dont know yet
a good sorce of info is flattrack .com.there are heaps of topics on tt/xt/sr500s
jim
Title: Re: Xt500 street tracker build.
Post by: curly001 on November 12, 2012, 04:27:13 pm: Paul have a White bros alloy swingarm F/S for an XT looking for $350(same as in photo). As for wheel sizes I'm running 18x2.15 front and 18x3.50 rear using a DS7/RD250 twin leader for front brake XT hub on rear.(http://i1200.photobucket.com/albums/bb328/curly3530/motard.jpg)
Title: Re: Xt500 street tracker build.
Post by: Tooheys on November 12, 2012, 11:06:22 pm: Quote from: curly001 on November 12, 2012, 04:27:13 pm
Paul have a White bros alloy swingarm F/S for an XT looking for $350(same as in photo). As for wheel sizes I'm running 18x2.15 front and 18x3.50 rear using a DS7/RD250 twin leader for front brake XT hub on rear.(http://i1200.photobucket.com/albums/bb328/curly3530/motard.jpg)

Thanks curly if the xr600 swingarm doesnt work out I might be interested. I'm starting to think the 100mm extra may be a bit much and throw the proportions out
Title: Re: Xt500 street tracker build.
Post by: curly001 on November 13, 2012, 01:50:49 pm: The white bros is only about 40 mm longer and will take upto 150 section tyre.
Title: Re: Xt500 street tracker build.
Post by: vmx42 on November 13, 2012, 02:46:39 pm: You can also get a custom, C&J style, flat-track swingarm from Richard Pollock at Mule Motorcycles. He makes a stock item for the TT/XT and can modify them to suit different tire specs.

His work is first class.

Check him out at: http://mulemotorcycles.net/

He is a great guy and he loves VMX as well

VMX42
Title: Re: Xt500 street tracker build.
Post by: steve234 on November 13, 2012, 04:04:33 pm: Mule rules!

Have been waiting to see updated pics of his KXYZ but nothing new there.
Title: Re: Xt500 street tracker build.
Post by: Tooheys on November 15, 2012, 05:09:43 pm: Thanks guys,

If the XR600 swingarm doesn't work out I will look into those other options. I couldnt find a swingarm on the mule website and it looked like he would only build a complete bike.
Title: Re: Xt500 street tracker build.
Post by: Tooheys on December 14, 2012, 02:51:52 pm: Have started to pull the motor down. Found a heap of gunk on top of piston, and the combustion chamber has a heap of carbon built up on it. I think the bore and piston look ok so was just going to hone the cylinder and get some new rings. From look of the head I think the head gasket was leaking so glad I tore it all down.

(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/9342606B-664E-4A0C-9CB3-086CAD748226-1953-0000010A00B531C9.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/82B43A06-49A1-4827-BF3E-8E6C87E69A52-1953-0000010A176B02B5.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/7F80EE3D-31A7-49BE-99D4-021ADF38C611-1953-0000010A1EB7C3A8.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/3E33513D-06BF-437A-802F-68957D2B6FB0-1953-0000010A40558D64.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/D6A82B0E-56C5-4FDC-AC31-46BACE52D4EC-1953-0000010A4DBB8CF6.jpg)
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/02AFFF65-73A4-4B7D-8F0F-6532F348339C-1953-0000010A831B44E2.jpg)
Title: Re: Xt500 street tracker build.
Post by: Tooheys on December 14, 2012, 02:59:31 pm: Are these marks on the cam lobes ok? They are still smooth to touch just look discoloured.
(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/C21C60C5-8BAE-4A6A-96C7-7F7561E1C06C-1953-0000010A721B1E27.jpg)

Rockers seem ok too.

(http://i58.photobucket.com/albums/g264/tooheys_1981/bike/2E423B37-61A0-40FC-BA5F-B9EF4F619AB4-1953-0000010A5D24AA1D.jpg)

Still trying to get the flywheel off so I can split the cases. I brought a puller but I cant get it to budge off the taper. Have soaked it in wd40 and given the end of the puller some love taps but it still wont come. Oes anyone have any ideas?