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Old 11-20-2013, 08:04 AM   #1
SONICJK OP
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Joined: Jul 2013
Location: Bell Buckle, TN
Oddometer: 27
New guy with a SR500 build

I've been lurking here for quite some time just never posted.
Figured the best way to introduce myself is to show you guys what I am currently working on.

A little background, I've been building old bikes for the last few years. I think the 500 is my 5th build.
My daily rider is a 75 400F that I did last winter:


I picked up an SR500 from a guy at a bike show, long convoluted story, but eventually I got her home for 100 bucks. In rough shape:


After a few hours of tinkering and she runs, quite well actually.


Next up was tear down:



I fixed the rear of the ugly ass frame:



Then I started blasting:


Here I got a bit side tracked powder coating a bunch of parts, some of them got used later some are just now pretty scrap.
The color scheme will me metal flake bronze, flat black, and creme white:



At some point in here I rebuilt the engine:

And got some Shinko 712's


Decided since this was going to be a road toy but with occasional jaunts into fields to do some powerslides and whatnot i got some 2009 WR250R front forks and some cheapy shocks that didnt get used

Lowered them 3"




Bent up a rear hoop:


CHanged up the top triple a little:



Built a seat from 3/16 aluminum:





And then things got interesting:



OOPS:


Bent up a new rear subframe from .120 wall 1" tube:

Welded up the gaping holes I left in the frame:


Narrowed the swingarm about 8mm tacked the subframe and built some shock mounts
And this is how it sits as of today:

SONICJK screwed with this post 11-20-2013 at 08:26 AM
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Old 11-20-2013, 04:08 PM   #2
JonW
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I like it! I also know only too well how you start off with an idea and then something comes along and you end up changing your mind. Its your bike so hell why not, nice to see that in action!

I have KTM forks on my XT500, shortening them was easier than I expected, mostly through threads on here, thanks those who posted those threads!
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Old 11-20-2013, 06:48 PM   #3
16VGTIDave
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Nice! I transplanted the same swingarm and suspension into my '82 Maxim 400 this spring. Had to install a stiffer spring as I weigh just a bit more than 190 geared up and the stock spring wasn't up to the task. I'm thinking of rear frame mods this winter. I'll be watching your progress.
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Old 11-21-2013, 04:33 AM   #4
pvangel
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Very cool, nice work!!!
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Old 11-21-2013, 07:04 AM   #5
SONICJK OP
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Thanks guys I appreciate it!
Its been fun so far.
Working on getting a tig to finish up the welding and make some more aluminum parts.

Quote:
Originally Posted by 16VGTIDave View Post
Nice! I transplanted the same swingarm and suspension into my '82 Maxim 400 this spring. Had to install a stiffer spring as I weigh just a bit more than 190 geared up and the stock spring wasn't up to the task. I'm thinking of rear frame mods this winter. I'll be watching your progress.
I haven't finished the welding to see if its going to work for me or not, but its from a 2007 ex250 which weights the same as the stock SR (mine should weigh considerably less) and I'm only about 150, so I am hopeful. Eventually I'll probably replace it with a nice shock but for now I *think* it should be fine.
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Old 11-21-2013, 07:18 AM   #6
bk brkr baker
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Sometimes , new guy with a ? whatever build is disappointing.
Not this time !
SR 500 's are great bikes and thanks for getting this one back in shape , and beyond with well considered mods.
Keep it up and I'll be watching and learning .
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Old 11-21-2013, 12:28 PM   #7
dlmarquez
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. Very nice! Subscribed!
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Old 11-21-2013, 02:51 PM   #8
SONICJK OP
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Quote:
Originally Posted by bk brkr baker View Post
Sometimes , new guy with a ? whatever build is disappointing.
Not this time !
SR 500 's are great bikes and thanks for getting this one back in shape , and beyond with well considered mods.
Keep it up and I'll be watching and learning .
Ha! Yeah I know all too well.
I'm only "new" here. I frequent other places

Hopefully going to get the shock mounts and all welded up tonight so I'll see how the spring weight is.
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Old 11-21-2013, 02:56 PM   #9
SloMo228
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Very cool. Looks like you know your way around a shop!
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Old 11-29-2013, 03:41 PM   #10
SONICJK OP
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Pulled the trigger on my tig tonight so final welding should commence soon.
But for now I made some gussets for the seat:


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Old 11-29-2013, 04:04 PM   #11
Canuman
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It's good to see a guy who appreciates the old stuff and does such nice work on it. I dropped off an '81 XT 250 that was surplus to my needs with inmate Jackpiner57, and his eyes lit right up. It wasn't cosmetically pretty, but the tank was straight and spotless inside, the head and swingarm bearings were tight, and it had a squeaky clean carb on it. Something about the lines of the old singles . . .

Looks like this one is going to be very pretty when you button it up.
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Old 11-29-2013, 04:26 PM   #12
Hohmie
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Way cool! I like it.
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Old 11-29-2013, 05:07 PM   #13
dhallilama
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rad little SR!
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Old 11-30-2013, 12:28 AM   #14
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Thats looking good

Where that web plate sits under the seat rail - don't weld fully into the corner... always leave room for movement/expansion to avoid stress at those tight points.

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Old 11-30-2013, 10:40 AM   #15
SONICJK OP
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Quote:
Originally Posted by Pigford View Post
Thats looking good

Where that web plate sits under the seat rail - don't weld fully into the corner... always leave room for movement/expansion to avoid stress at those tight points.

Thanks pigford!
I'm also going to move the gussets out the the inner or outer side of the tube for more strength haven't decided which yet.

I appreciate the comments guys!
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