Monday, May 15, 2017

Project XTracker: Front end mounted


I got a couple hours in on the project bike this weekend and managed to get the GSXR front end mounted up. It went on surprisingly easy and didn't need as much machining as I thought it would.
The XT500 stock has individual ball bearings in the steering stem. I bought a conversion kit for taper roller bearings that comes with the 2 bearings and 2 races to press into the frame. Luckily the steer tube bearing diameters on the GSXR triple clamps are the same as the XT500 so no special machining needed there.

Wednesday, April 26, 2017

Project XTracker: More parts!

Project name update - I decided to start calling the bike project XTracker. It's an XT 500 and will be styled as a street tracker.... self explanatory... and I can use #XTracker on social media to track project posts.
New parts this week:
The rest of my exhaust parts came in. Stainless 12" reverse cone megaphone, 18degree bend and mounting bracket from Cone Engineering. This will match up nice with the stainless low pipe header. Going to hit up my buddy Kevin the TIG welder to fab these babies up.

Custom aluminum 40 tooth rear sprocket from PBI sprockets. I ordered the sprocket custom machined to my specifications and it shipped the same day! It wasn't cheap - $100 usd shipping (plus $20CAD duty... grrr) but should do the trick nicely. Time to sort out the hub adapters....

Tuesday, April 18, 2017

Project Bike: Dad's XT500 - Old pics

Here are some pics of  the XT in action that you probably won be able to ever do again. Wheelies on the Lake Huron beach and riding on the Port Elgin harbor ice in the winter. The ice riding shots show a different bike but its the same XT engine in a different 'framer' chassis.


Monday, April 17, 2017

Project Bike: Dad's XT500 - Exhaust header & rear brake caliper

More new parts! My exhaust header came in this week. It's a Hoos Racing 1-3/4" stainless low pipe.


I sourced out a better rear brake caliper to fit my rear brake setup. Its a Brembo unit that came stock on a number of Ducatis. I got this one of a friend (AJ) that I race flat track with who is also into road racing Ducatis. I think I'll eventually paint the caliper black and keep the Brembo logo polished aluminum.

Project Bike: Dad's XT500 - In Ayr


My parents came down to Ayr for Easter weekend and brought the XT down with them. I snapped a few pictures of the bike in its current state before I tear into it.


Check out the high flow oil line that Dad added recently

Thursday, April 13, 2017

Project Bike: Dad's XT500 - Grub screw mod

As I mentioned before, the engine was making a funny ticking noise after Dad got it rebuilt and up and running. A little internet research found a possible solution - The grub screw mod. This is where the top of the rocker box is drilled and tapped to use grub screws to put pressure down on the rockers. The problem stems from the bores where the rocker arms pivot getting worn and allow the rockers to move. This is likely why we saw the exhaust rocker so warn when we tore the engine down. Here is a video where you can hear a big improvement in the engine noise after the mod is done.



EDIT- Here is some more info on the grub screw mod:

Wednesday, April 5, 2017

Project Bike: Dad's XT500 - Front end and more parts


I drilled the top GSXR triple clamp for the handlebar mounts to get an idea how it will look & fit. There is a good chance I can use the stock top triple clamp and steering stem based on the rough measurements of the XT frame. 
I took another trip to Zdeno to find a new, smaller rear brake caliper. I didn't have any luck but I did come a cross a 6 piston front caliper off a 1999 Kawasaki ZX7. I traded in the 4 piston caliper and the rear brake system I had previously sourced plus a couple bucks $$$. This will give some more power than the 4 piston unit I previously had and will match up much better with the large master cylinder I'll be using.

Friday, March 24, 2017

Project Bike: Dad's XT500 - Sourcing brake parts


I took another trip over to Zdeno Cycle to find some braking components. I picked up a pair of 310mm floating front brake rotors off of a 1996 Triumph Trophy 1200. It took me a while of sifting through the 'Rotor Room' at Zdeno to find a good matching pair of rotors with a mounting bolt pattern that would sit outside of the wheel bolt pattern. I'll only be running one front rotor and I'm going to use the big 310mm rotor on the rear so that the caliper will sit over the sprocket.
I also picked up a rear brake system - master cylinder and caliper off a 2006 Suzuki GSXR 1000. The caliper looked perfect - nice and small and the 2 bolt flange mounting.... But once I got it modeled and stuck into my rear wheel computer mock-up it became apparent that its too wide and will interfere with the cast spokes of the wheel... See image below. Now I need to find an even smaller rear caliper - maybe a motocross style with a single piston.

Project Bike: Dad's XT500 - Up and running!

Another update on the restoration. Dad got the bike up and running and it sounds pretty good for a 40 year old bike. A bit of ticking on the top end so were going to look into the grub screw mod to the rocker box to counter the effects of a worn rocker pivot bore. Cant wait to hear what it sounds like with a new higher flowing exhaust later on in the street tracker phase. Damn it looks good!

Friday, March 17, 2017

Project Bike: Dad's XT500 - Works Connection Clutch Lever

My new Works Connection clutch lever assembly showed up this week for he street tracker build. This will add some nice touch to the controls and bring a little motocross styling to the build. These clutch levers aren't cheap but are well known for being the best. Super smooth action. I ordered it with a hot start lever built into the perch. This will be used for the decompression lever to help with starting the big single... This will also eliminate the extra lever needed for the decompression system.