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Discussion Starter #1
built a few of these quite a few years ago but with the recent release of the BRC500 it made me want another 500 in a modern chassis. will be great for hill climb events and nothing much else lol but fun either way.
with all this in mind it just so happened I had a spare 500 lump and a ktm 450 chassis to build another .
 

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Discussion Starter #3
it's a pretty simple conversion but cheaping out like I've done with a older chassis isn't cost effective if you want a nice looking bike. even though this bike had only done 100 hours everything needed restoring which takes time (and money!)

my last one I'd built was onto a new 2012 chassis and was completed in 2 evenings from start to finish.
It took longer that that just to clean this one.

2 drawbacks with previous 500's I've had are the heavy clutch and kicking the beast when tired.
I've sorted with a decompression cylinder head and a magura clutch conversion so should be nicer to ride.
 

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Discussion Starter #5
lol thanks chawnz, I have my moments, not many but a few.
should hopefully be finished in next couple of weeks
 

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We haven’t had a good rebuild thread on here for years.
 

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Bloody marvellous matey! Don't forget to fit a STIC block to the carb! :)
 
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Discussion Starter #11
thought I'd update this . loads of work done (I mean money spent)

mounts are ready to weld tomorrow.

bought some lovely goodies.
39mm oval bored airstriker.
scalvini silencer
rekluse cx . i cant wait to ride a 500 that wont stall! since a electric start was out the question a rekluse seems to be the answer.
 

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Discussion Starter #12
had a 2018 caliper and hose. wish I hadn't bothered as it was a bugger to bleed.
buying a rekluse seemed a good idea but as this is a 1987 motor it has a narrow clutch basket and kickstarter case so I've had to order a billet basket and new case from a later model.

I've never liked the PDS bikes handling and I have a newer linkage bike I could do the conversion on however I'm going to try get to grips with this set up. have RSS set up some open cartridge forks and maybe a trax if I can find one .
 

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Discussion Starter #16
yeah I'll update it with some pics over weekend.
some major bike porn to look forward to
 
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