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Recently, I bought a 86 VF500 roller with a title. I owned one of these back in the day, and always thought it would be a great idea to own one again. 20 years later, I am living my dream :) I do have plans for this build, but first things first, I need to get a 1978 YZ400 thumper nestled in the frame and get it running. I'll ride it like that for awhile, and after that I will look into upgrading most everything. Probably a complete front USD fork conversion, upgraded rear shock swap, some frame stiffening, brake upgrade and new tires. As far as bodywork goes, no need to change anything there. I have always thought the bodywork was amazing on these bikes. I'll see how the stock rear sets will feel with clip-ons. If it is not right, I will look into moving the stock ones or adding something different. As far as the engine goes, when the time is right, it will get a fair amount of attention. A small overbore, piston and rings, rebuild crank, new seals, reed valve, 38mm flat slide carb, skimmed head and an exhaust system. With these mods, I feel that I should be pushing around 55-60 hp. And I'm really hoping that the DT400 electrical system is a direct bolt on affair :eyebrows: If not, I'll have to figure that part out later.
 

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Here are some pictures. I know it's not much to look at right now, but I promise you, if you stick with the build, you will not be let down. A suggestion was given to me to add some rubber engine mounts, much like the Harleys have to take away some of the vibration from the engine. I really like this idea, and will look into those when the time comes. Engine is arriving to me next Friday. In the meantime, I am still looking for a cheap donor bike. If anybody has one sitting around, let me know :)
 

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I have been searching endlessly for random parts I need to at least get this bike running and stopping. I have found most parts needed to do at least that and keep the vintage look of the VF500F. Parts are going to start arriving by the end of this week. I'll post some pictures of the 'new' parts when I can :)
 

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Hey guys, just a quick update on my little project here. Engine came in yesterday and I quickly mocked it up this morning to see how it fits. I'm surprised how much room it takes up in that space.


It's not exactly where it needs to be yet, it's just for my satisfaction that I see it in there:) Other parts have been arriving and will quickly make their way on the bike for a total mock up. I found a lighting coil that I will buy this weekend, and am looking for a R/R to convert it to a 12V system. All in all, I am happy with how everything is working out.
 

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I have been busy with spring time obligations, but have found a little time to tinker with the project.
Just a few things happening:
I have a friend who has access to a machine shop making me a top clamp. I wanted to use clip-ons, but don't think the geometry is correct for that unless I push the foot pegs back some. So I will have pro taper bars instead.
I also have a complete front brake assembly coming to me in working order. I don't want to use the anti dive mechanism, so I will simply remove that side from the circuit so I will only have a single front disc. I like the idea because it allows me to shed some weight. I will also drill holes in the rotors (front/back) to aid in braking and also to shed some weight.
I located a battery tray for a good price and have installed that.
A free Ninja 250 tank is now in my possession. While it doesn't really fit, I like the shape and will try to 'make' my own tank by cutting this one up and shaping some new pieces. I'll tack it in place, but will have a professional weld it up. (This should be interesting)
I need to figure out which rear sprocket to use. The only thing I know right now is that it needs to be .100 of an inch thinner to match the one on the YZ engine.

Adding a clutch perch so I can use a stock clutch cable should not be a problem, but I need the front brake handle assembly so I can figure out how to retrofit a stock throttle cable to the YZ's carb. I may have to have one made if it doesn't work together.

I also have a stock YZ400 kick starter coming my way. I think it'll have to be heated and bent a little to make it miss the foot peg, but only by an inch or so.











 

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I thought about this as i have honda vt 250 rolling frame

Engine is knacked how do you line up the engine sprocket to the chain line

and the rear sprocket is there a postion it needs to go .
 
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