List of work done on the XS500 "#7" and a bunch of pics

what it started as

same bike?

Frame: Stripped down and all unwanted tabs removed and smoothed down. The angled down tubes from the rear shocks, to the bottom frame where cut out to open up the rear wheel area, and to make room for the R-1 rear sets. Tubing from a kz twin where welded into the frame, from the shocks to the cross brace on back of the frame. 1/4 inch steel brackets where welded in to mount the rear sets. Then welded a 16 gauge flat steel across the top of frame to close off under the seat. To act as a hidden fender and also mount all the electric. Then frame along with swing arm where powder coated in gloss black.

Wheels: Rims and rotors where drilled out with 1/2 holes & powder coated sun yellow and wrapped in new Bridgestone Spitfires. 110/90/19 front. 120/90/18 rear.

Tank: Stripped down and painted rustoleum sun yellow. Relined inside and carbon fiber Yamaha decals added to accent the rear cafe seat. The gas cap was wet sanded down for an aluminum look.

Cafe seat: The seat works as the same as the stock bike. The original seat pan was cut down and the one off fiberglass seat was molded to the seat pan. It was finished with a 3-m dinoc carbon fiber wrap. The custom seat pan has 1'' foam and covered in flat black vinyl. Tunnels where made under the seat to the lighting so nothing is hanging underneath seat when opened. A quick release plug disconnects the wires from the seat for easy removal of the seat. 2 hinge pins and disconnect plug and seat comes off. Finished off with #7 European style racing plates Decals with the 7 cut out to show the carbon fiber behind it.

Front # plate: A three piece 3 plate was made to match the 7's on the seat out of 16 gauge steel.

Front end: Stock forks and triples. The top triple tree was grinded down and reshaped to accommodate the new Woodstock clip-ons, Emgo throttle. All controls and levers are from a R-1. Mini brake reservoir. New N.O.S tachometer with high beam indicator was mounted center with aluminum brackets. Fork legs painted satin black and have new oil seals. The stock fender mount was used as a fender brace. Whatever was not new was stripped and painted. Triple trees-satin black. Head light ears gloss black, to break up the parts. The head light bucket is from a 76 honda cb 360. Bar end mirrors are aluminum to bring in the aluminum on the exhaust.

Engine: new stator and generator installed. The engine has a little over 20,000 miles on it, the previous owner was a kawasaki mechanic and it runs without any issues. The engine was wet sanded starting with 400 grit to 2000 and polished. the fins on the head were painted with 2,000 degree engine paint. oil breather that matches the filter pods.

Carbs: Rebuilt by a professional in N.C. Then jetted - just the main jets where changed. It is well mannered at low r.p.m. but once it hits around 6 grand it opens up and screams.

Exhaust: Custom made using the stock headers welded to an aftermarket pipe. Name unknown. Then baffle cut down to half and painted with 2000 degree aluminum engine paint to protect it from rust then wrapped with header wrap. The header wrap was stitched up at the joint where the headers meet the pipe and at the starting and end point, to help keep it from fraying faster. And a custom aluminum bracket was bent up and polished to mount pipe.

Lighting and electric: The rear lights are all L.E.D. The headlight is a H-4 bulb with the blinkers "L.E.D." are integrated in the headlight for a clean look. l.E.D. flasher. New starter solenoid, batt, N.O.S. coils, condenser and points. The electric harness "which is all color coded" is custom made and ran thru a fuse box that breaks up all the lighting and ignition system. So you do not lose all lighting if fuse goes. Front lighting on one fuse. blinkers on another. rear running light. and brake lights all separate. The main key is hidden under the seat to give a more clean look. main power from the ignition switch is ran thru the kill switch enabling to kill all power to bike. and if unattended switch the key off and no one knows how to turn it on. seat latch and wheel lock both work. The electric box is rubber mounted to the top frame plate under the seat.

Other new parts: Both brake lines, clutch and throttle cables, zinc o-ring chain, side mount license plate, Wanzig R-1 rear sets, Woodcraft clip-ons, Bridgestone Spitfires, All Balls wheel and steering bearings, brass swingarm bushings from TC Bros. and I don't even know what else. The whole bike was gone over. Now I'm not saying every bolt is new on the bike. Certain original bolts and other parts where left original to keep the soul of the bike.