HL 500 (lite) replica build

Discussion in 'Old's Cool' started by pvangel, Oct 27, 2013.

  1. pvangel

    pvangel Team AARP

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    Old school...that's why it is posted here!:D
    Actually I think Kawasaki's still use them on there motocross bikes, those nuts are actually new from Suzuki....period correct!

    So ONE more trip to the local dealer, picked up the seal and ordered the cam key.

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    Than on to a REAL HARDWARE STORE! This is 1/3 there nuts and bolts wall, amazing what is in this little hardware store.

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    Bought some 3mm pin stock there so I can at least put it together temporarily....

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  2. pvangel

    pvangel Team AARP

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    Cut a pin to fit, worked fine.

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    I could not remember how this went together so probably spent 1/2 hr on it before I opened the manual and saw the nice big exploded picture:eek1

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    All buttoned up!

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    So now I could finally close up all the electrical stuff!

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    Checked for spark and it actually had some, might be able to actually start it soon :clap:clap:clap
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    Because I am on an unlimited budget on this project:D I sprung for a new sparkplug!

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  3. pvangel

    pvangel Team AARP

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    Wiring and cables all set, Tank mount padding in place...I'm getting excited!

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    I never drilled the whole and mounted the petcock permanantly so took care of that.

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    All plumbed up and clearance looks ok.

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    Almost forgot the oil :huh

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    Some petrol to aid in combustion.....

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    Ass to the door in case it actually starts....

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    And lets give it a try..............................
  4. kenny61

    kenny61 Crazy Idiot

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    iS THAT kATONAH HARDWARE?
  5. Scootern29

    Scootern29 Been here awhile

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    Lookin good PV, I have a question. Are the shocks parallel with each other? In the one pic it looks like it is out of square. It may be the photo, but, I hope they don't bind if they are not square.
  6. pvangel

    pvangel Team AARP

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    Ridgefield Ct. They have Metric bolts in most sizes both regular and stainless. Not as inexpensive as Fastenal but very convenient.
  7. pvangel

    pvangel Team AARP

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    Yes, all square. I used the stock mounts on frame and swingarm.
  8. kenny61

    kenny61 Crazy Idiot

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    I wnet to fastenal in danbury over by fedral road once all the would do is sell boxes of a 100. No individual pieces
  9. pvangel

    pvangel Team AARP

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    So......Bike started up, took a few kicks and sounded GREAT! Not to loud which I was worried about.

    Would have loved to go up and down the drive but this friggen winter won't stop :cry:cry:cry

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  10. kenny61

    kenny61 Crazy Idiot

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  11. pvangel

    pvangel Team AARP

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    Fastenal In Bedford Hills on Adams Street has bins you can pick out of or I gave him a list of bolts for this project and everything comes in separate bags.
  12. kenny61

    kenny61 Crazy Idiot

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    didnt know there was one there. good to know thanks!
  13. pvangel

    pvangel Team AARP

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  14. JagLite

    JagLite Long timer

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    Fantastic!


    Looks magnificent and it will be a treat to ride :clap

    Bravo Sir!!!

    :wings
  15. pvangel

    pvangel Team AARP

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    I was dying to bring it outside today so cleaned all the snow off the driveway and let the sun hit it for awhile, took care of some honeydoo stuff for Sister Mary Margaret and then I just had too....

    Bike started right up and sounded great, one of the reasons I put the wrap on was to keep it quiet which I don't think it needs. The red was burning off right away anyway...we'll see.

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    Clutch was slipping a bit and I kind of knew I should have replaced it so will do that now. I ran it through a couple heat cycles and it fired up easily each time, seems to have a bit of pep but tough to tell now.

    Bunch of adjustments and finalizing some things but all in all very happy with everything!

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  16. RickS

    RickS Been here awhile

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    That is a very nice build! Great job and write up.
  17. pvangel

    pvangel Team AARP

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    Thanks RickS!!!

    These came in today....

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  18. kenny61

    kenny61 Crazy Idiot

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    Side covers ?
  19. pvangel

    pvangel Team AARP

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    The HL200 will go on the sidecovers and I told him to make the tank stickers as well so they match.....:wink:I had too
  20. kenny61

    kenny61 Crazy Idiot

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