Okay, so I’ve been wrenching on bikes for a while now, and I always wanted to get my hands on a classic Yamaha SR500. Finally snagged one a few months back – a bit rough around the edges, but with good bones, as they say.
My whole goal with this project was to bring it back to its former glory, but with a few personal touches. Not a full-blown custom build, more like a respectful restoration with some subtle improvements.
Getting Started
First thing I did was just assess the situation. The bike started, which was a huge plus, but it ran pretty rough. Lots of little things were busted or missing. The wiring was, let’s just say, “creative.”
- Tear Down: I basically stripped the bike down to the frame. Took photos of everything as I went. This is crucial, especially if you’re like me and tend to forget where things go after a few weeks.
- Cleaning: Oh man, the cleaning. Years of grime and gunk. Lots of degreaser, elbow grease, and wire brushes. Got the frame cleaned up and ready for inspection.
- Frame CheckLuckily no cracks on the frame, so that was a good thing!
Engine Work
The engine was the heart of the project. I knew it needed some love.
- Carb Rebuild: The carburetor was a mess. Completely disassembled it, soaked everything in cleaner, and replaced all the jets, gaskets, and the float needle. This made a huge difference in how it ran.
- Valve Adjustment: Checked the valve clearances. They were way off. Adjusting them is a bit fiddly, but not too bad once you get the hang of it.
- Oil Change: Fresh oil and filter, obviously. Used some good quality motorcycle oil. Don’t cheap out on this!
- New Spark Plug: Such a simple thing, but always a good idea.
The Rest of the Bike
With the engine sorted, I moved on to the rest of the bike.
- The Brakes: Rebuilt all of them, because safety is the most important thing.
- Electrics: The wiring was a nightmare. I basically rewired a good chunk of the bike, using a simplified wiring diagram I found online. Got rid of a bunch of unnecessary stuff.
- Suspension: The front forks were leaking. Replaced the seals and oil. The rear shocks were pretty worn out, so I replaced them with some slightly upgraded units.
- Cosmetics: This is where I spent a lot of time. Cleaned and polished all the chrome. The tank had a few dents, so I learned how to do some basic bodywork and paint. It’s not perfect, but I’m pretty happy with how it turned out.
- New Seat: The old seat was ripped and uncomfortable. Found a nice, used, original-style seat on an auction site.
- New tires: Put on some fresh tires, I think that’s a must-do.
The Result
It took a while, lots of late nights in the garage, but it was totally worth it. The SR500 now starts easily, runs smoothly, and looks fantastic. It’s not a show bike, but it’s a solid, reliable, and beautiful classic that I’m proud to ride. I even took it for a longer ride last weekend, and it performed flawlessly. There’s just something special about riding an older bike that you’ve brought back to life yourself. If you told me at the beginning that I would have been able to do all of this I wouldn’t believe you. It was a real challenge, but a super rewarding experience.
