Yamaha XT500 Tracker build thread.

So its time to start a build thread. The pictures above are the photos of the day I brought the bike home. Originally I was thinking of going with a brat style but decided to go with a tracker instead. Stay tuned and I will continually update with the progress

So don't mind the carb missing I needed to clean it out due to the bike not running. Found sand jaming the float needle. So cleaned out carb and adjusted floats and finally got this thing fired up. Onto the next bunch of photos. Changed out the bars started to paint the tank. The forks also had been slid up in the tripple clamps to lower the bike. So I slid them back down. Then went on to weld a martini can exhaust onto the open header and tinker on some random shit.

So time to figure out how I'm going to make my rear fender.
So I took I huge peice of 16 guage and scored it 6 inches in with a 9 inch gap and then 6 inchs to the edge again. So folded it into a big rectangle then I had to shape it. So I cut it to the shape I would like but it ended up still being to square and boring

So I decieded to cut straight down the center and flare it up

There it is roughly mounted by a paint can. So till need to make a seat pan to fit the fender and mount the tank and finish painting it. Stay tuned for some more pictures.

Lookin good bud now get to work!

So the saga continues here's what I've gotten done today before the crabby wife came out and bitched.


Coming along nicely

I like it, looking forward to the end product.

Cool. I like these little tracker builds.

Thanks guys. So I burnt a couple hours out there again. Didn't get as much as I had hoped. Shit kept fucking up but I got em sorted. So I finally got the kick stand done. I welded 2 tabs to the frame and 1 to the kick stand and 1st test that motherfucker bent so then I had to make up 2 more tabs and weld those to the kick stand. When in doubt hit it with some overkill.

Also put on the new chain. Adjusted the adjustable hard tail struts and then went to install the new chain then that motherfucken chain hit the swing arm. So then had to fuck with the struts and pretty much put em back to where they where at. But got the new chain installed. And also modified a tail light I got now it will tuck nicely under the fender.
Stay tuned the Mrs is out of town this week so I will get some shit done.

Also got the seat pan welded.to the fender

Don't forget to safety wire that chain master link for all the thumper power!

Originally Posted by Tattooedolive

Don't forget to safety wire that chain master link for all the thumper power!

fo sho. i still cant believe that that kick stand didn't hold with the orignal tabs. its strong as fuck now.
i set it on the kick stand and it just kept leaning hahaha.

So some big steps toward today. Got the tank mounted. The tank is an Sr tank had to modify it and make some custom mounts. Also got the headlight I picked up at the swap meet. Made a custom bracket that attachs to the lower tree.

Need to finish painting the tank. The teeth aren't done and need to finish the eyes and so on. But its finally looking like a bike.

Alright so been a while since I posted some updates. Even with the ridge on the back fender still didn't like the box look of it. So trimmed the back of it and its looking better then threw a coat of flat black. Also realized I wasn't gonna get the tank to look like I'd want so I just grey d it all out. Then officially got the tank 100 percent mounted replaced all controls and cables. Threw the grips on and plumbed the tank. Got to run her for an extended amount of time. Got her nice and hot for the first time and actually got the.clutch freed up and took her for the first voyage around the neighborhood. Now just gotta get the lights wired up and tie up a few loose ends.

Next to do is cut some foam and upholstery it. To get the seat done.

And now it's going for boner time

Some more progresss on this thumper. Stephen the owner of the bike and the one that started this thread got some plates ordered up from a bloke on the chopper underground. Real nice product for your 17mm axle chopping needs and there 3/8 so tuff as nails.

Axle plates going in


Made up some new axle spacers to allow for the 19mm of widening.



Got everything tacked in for the hardtail and other stuff. Cut out all playing and started mocking up a fender after sectioning it. It was a old trailer fender I ha laying around. Definitely liking the look of this flat tracker build.



Messing around with his exhaust and through a ammo can up there for filler and possibly to hide some stuff.

Made 1 of 2 motor mounts tonight and trying to decide which way to go with the rear fender. I'm more partial to the first picture where the fender does not drop below the seat. I think it looks cleaner.

Well I guess nobody follows a build tread that is actually updated so fuck it I'm gonna post anyways.

Got the fender for the rear mostly done but still needing to finish weld it as well a majority of the bike.



Also with these XT500 the kicker goes almost 160 degree from its upright position so figuring a new rear brake setup and peg setup was in order.





Still lots to do and switch out the mock up parts for new parts and what not.

Hopefully the tank will come tomorrow

Im so so excited to get this thing finished.

Making some head way on this xt. A lot has been done from last time I posted on here, got the tank finally and it was in a lot less shape than the buyer listed. Bunch of dents and what not. Set it on the back bone for mock up.



Then Stephen the owner came over for a test fit.



Got the motor cleaned up and put back in after getting it sprayed.



Next made a manifold to side mount the carburetor. Need to still add a bottom brace so it dosent fatigue over time.








Ripped off the old seat that was originally going on for the more speedway looking bike and decided to run a solo sprung seat. Mocked up




Also some new biltwell gum grips.





Came over for another test fit. Put on some weight since last time.



Rear fender sprayed and mounted.