This is my first post on here so hopefully I don't mess it up. Also hope I don't piss of any "purest" people out there as this is in no way a restoration and I have no interest in restoring it to original.
This is what I have been working on the last few weeks. I picked up an xr500 about a month ago for $300, it started but had no clutch lever so I didn't get a chance to ride it. I noticed later that it has a White Brothers aluminum swing arm and possibly upgraded shocks but I really don't know.
Its pretty rough but a running bike for $300 I wasn't going to complain.
I decided i wanted to build it into something that was kind of a cross between a bobber and a scrambler and use it mainly for commuting across town to work, but still be able to tackle mild single track.
I went though my garage and was able to come up with a front fender off of a newer honda 150r (i liked how small it was), and a rear fender off of an 04 crf250x so it has the licence plate holder an led brake lights. the front fender bolted directly on but he back took some modifying.
From ebay I found a 21" wheel for the front (81-83 xr500) but the drum was a 131mm max dia while the original 23" was a 141mm max dia. this was quite a disappointment but I guess i should have done a little more research. I ended up putting the brake hub from a 83xl250r into it, its not perfect but it works for now.
I then started to build a seat, while the original was quite comfy, it did not have the look I was after. I started with cardboard until I had a shape I liked. Then I cut, bent and welded it all together, luckily at work I have access to a nice break, shear, welders and scrap metal.
It turned out ok I thought for my first attempt at a seat pan. Next I put some closed cell foam on it from a sleeping pad I got from the sporting goods store. I wanted a low profile for the look so the thickest part is only about an inch thick. I used a steak knife to trim the foam and it worked alright, I ended up covering all the edges with gorilla tape to smooth it out.
I then covered it with marine vinyl I found at Jo Ann fabric. Instead of cutting and sewing to get the material to fit right I used a heat gun which stretched the material enough for a "good" fit. I used 3m spray glue and a metal plate on the bottom to secure the cover, its holding so far.
Here it is with the seat all finished. I also found some horrendously cheap foot pegs for a yz bike from (99-05), I think they are a cast steel of some sort. I guess you cant complain much for $15. they required a little grinding to fit but seem to work good enough.
I was finally able to take it out this last weekend and had a blast, it runs way better than a $300 bike should. I had to remember how to engine break as I usually ride a 2t with good brakes, it turns out they went away from drums for a reason. My seat wasn't quite as bad as I thought it would be out on the single and double track. We also went out to some hill climbs and the 500 impressed me with amount of torque it delivered at any rpm. This bike is much different than anything I've ridden before between its torque and having almost no weight over the back tire.
As far as the seating position goes, I actually like how compact it feels. I also think the low profile seat goes with lines of the bike rather well so I'm pretty happy with how it turned out, especially for being my first try at making one.
Next for this build I would like to make it street legal. I'm not looking forward to figuring out whats going on with the wiring and converting from 6v to 12 as the components I have are 12v and i would like to have the front light be a LED light bar. I have a different bike that I am thinking about adding lighting to using a rechargeable battery like a Milwaukee m12 or something, so maybe I will go that route.
I would also like to figure out an exhaust for this at some point so i don't get kicked out of my neighborhood.
Thanks for reading, I'd love to hear what you think and any suggestions you may have.
2016 Yamaha YZ250F vet owned and is extremely clean. Perfect condition one owner bike. I challenge you to find a cleaner used bike than this one. Motor is all stock and approximately 40 hours on the bike. This bike is the best bike I've had in a long time and wouldn't be selling if I wasn't going back to kart racing.
ProTaper Handlebars Reed Bend
Protaper Twister Throttle Tube
Cycra Skid Plate
Protaper Sprockets w/ RKGB520MXZ4 Chain
Dunlop MX3S Tires
Twin Air Filter w/ NoToil Super-Flo Cage
About 10 hours on Factory Connection Rebuilt Suspension
Get C1 Wireless Hour Meter
Front wheel is a DID LT-X w/ Bulldog Spokes laced to stock hub
Blue CV4 Y-Hose Kit
I have a question about my xr250. Its having problems with the kickstarter and I came here to see if anyone had some insight. I was riding it the other day, and I use it for a sort of long commute so i was going 65-75 for about 30 min. The bike shut off, tires didn't lock up, but i pulled the clutch in and rolled off to the side. tried kicking it over but it was immediately locked. You can see in the picture where the kickstarter stops at. its completely dead locked at that point, no give at all. rolls in neutral still. brought it home, opened up the oil to check for anything strange but looks clean. as far as the bikes condition previously, it has an oil leak coming from the head, i think i did it the few months i had it. the sleeve that holds the exhaust into the head popped off, rode it like that for a few days before replacing the part. a week before this problem. I'm completely amateur to bikes, but i want to take a crack at it and get this thing fixed up. the oil level in the bike may have been slightly overfilled as well. i was topping off because of the leak. where would be the best place to begin here?
Thanks for helping
Hey my buddy has a honda crf450r and started making noises recently, or a while ago, we thought nothing of it, thought maybe the chain or something, the bikes always coming up with problems, but they got louder, and so he stopped riding it and is gonna look into it. Does anyone have any ideas what it is? To be specific, it sounds like a clanking that sounds like if your chain is loose, but in the top end like where the cams or piston is. Any idea?