Custom 1983 XV500 - Build recap

[thirstforspeed]

Hey guys,

I spent the last 2 years building this bike. Its up for sale now, but I am in no rush, so that means I will probably be doing stuff to it this winter (this project never ends - just the way I like it).

Here is a quick recap of the build. The full show is also available HERE on my blog.

What it started as:

First mod was a fork conversion. I bought an 06 ZX6R that I took apart and parted out so that I could be sure that I was working with a straight front end (never can tell with front ends from the wrecker). I did a little maching work on the stem so that I could use the stock XV stem in the ZX6R lower tree. That way the bearings stay stock for later. Much easier IMO than screwing around with weird bearing sizes and stems to make it fit.

Second item was a rear wheel swap from a Gen II XV1100 so I could rid myself of those gross swoopy double5 spoke things.

This required a complete swingarm and final drive swap from a Gen I XV750/920 to be able to work. Those swingers bolt right up to the XV500 frame. No mods needed at all.

Fat tire was put on. 170/80/15.

Next up, subframe and electronical whizbangs.

 

[thirstforspeed]

Subframe is next. Bought a kit from Dime City that goes with their seat so that I can get the kick-up right on the tail, and also get some raw materials for fabbing the subframe.

made a little trunk for it too.

Electrical doodads: LiFePo battery, m-Unit, custom GPS speedo/tacho, custom harness, GSXR controls, TCI retained

 

[thirstforspeed]

Used a Termi can from a Multistrada

Those pics are how I ran it last season. Stripped the stock tank and then coated with Penetrol and clearcoat. This past winter I made a new custom tank and cleaned up the engine covers.

 

[thirstforspeed]

I made a new tank using a spare XV500 tunnel and an 83 CB900 tank. Lots of metal work here to make them fit together. Also grafted on the XV500 filler cap so I can use the stock key to open the filler and trunk. Still runs with the stock XV vacuum petcock as I have found this setup to be very reliable.

Here is how I retained the tank. Pins in the tunnel go through a tab that is welded to the subframe, and secured with a hairpin, all is located with stock locating hole at the rear. This happens at the back end of the tank. Front end is stock virago.

XV filler neck and cap is added

Fitting the two pcs together. extensive use of CAD (cardboard aided design).

 

[thirstforspeed]

Inside sealed with KBS Tank Sealer Kit. 10/10 would recommend. did a great job.

Bondo'd and prep'd for paint

Underside gets satin black, top side gets Honda White and Honda Type R Red with a black stripe, then cleared.

Lots of clearcoat and wetsanding later; and also new paint on the engine covers

This is how I have been riding it all summer. Its up for sale now because my wife says I can't have another until I finish my other project (CB550) and sell this one. I want a VTR to hypermile across Canada.

If I don't sell this one before the winter, I will most likely make a new full SS exhaust system for this, tuned primaries, anti-drone, etc over the winter. And maybe think about converting this bad boy to fuel injection. That should be easy and cheap, right?? We shall see.

Its probably already the world's most expensive XV500. I don't know if that's a good thing, but I am super proud of what I have done to it.

 

[stevie t]

I saw this bike the other day on the street.
Nice build.

 

[SVeezy]

Very nice build


Sent from my iPhone using GTAMotorcycle.com

 

[Mango Rider]

I saw this bike the other day on the street.
Nice build.

If that's the case, I'm really glad it's in use still! Wonder if OP sold it or if that was them riding it.

Sent from my LG-D851 using Tapatalk

 

[stevie t]

Rider said he bought it.

 

[thirstforspeed]

Rider said he bought it.

OP here. I sold this a while ago - march of 2015 i think. Went to a guy in Newmarket who then flipped it for a 1500$ profit in a few months, then i ran into it on the streets of TO and the guy that bought it from the dude in Newmarket said that the Newmarket guy basically replaced me in the build story with him (saying he built in conjunction with Ted Rose or something, i cant really remember, dont really know how Rosey Toes got pulled into the story, but whatever).

Good to see that its still out and about. i really miss that bike, and am getting the itch to do another Virago.

 

[stevie t]

The tank had been rattle canned black. I thought it looked out of place with the rest of the build. Rider did say he dropped it in the rain.
Again, nice work.