Xt500 street tracker build.

[Tooheys]

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.


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.


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.



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



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.


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

[Tooheys]

Hmmm typical newb who cant get photos to work . Off to the "this is how you post photos newb!" Thread

[TT5 Matt]

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

[steve234]

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

[firko]

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.

                                                                 
                                                                 
                                                                 
                                                                 

[Tooheys]

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.

[pancho]

 Great project Tooheys!
 Re racing on club days-DO IT DO IT DO IT!
Cheers pancho.

[ola_martin]

You work on your bikes in a skirt??
 

[Tooheys]

You work on your bikes in a skirt??
 

Haha no they are boardshorts with an unfortunate pattern on them, so they only see the shed nowdays.

[smed]

I thought you were in your PJ's & slippers

[Iain Cameron]

Ive got a Cycleserv TT/XT up to the "F" model I can loan you if you need it . Iain

[Tooheys]

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

[jimg1au]

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

[curly001]

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.

[Tooheys]

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.

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