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-   -   my sunday driver... (

84rzv500r 21st December 2016 18:28

my sunday driver...
for those days when i want to ride without blonde barbie...

99 XL1200s forks and shocks are a bolt on...

supertrapp stainless cans are a TIG on job to a set of used spare OEM mufflers that I plasma cut the guts out...

swing arm spools are just off the shelf stock...

steering damper is one I got from Steve Stortz and made a bracket to bolt to the upper engine mount...

IXL2Relax 21st December 2016 20:04

Here ya go.... Nice bike...

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wilkin4 21st December 2016 22:01

Wow, very nice bike !!!!!:clap:clap:clap

CT XR rider 21st December 2016 22:39

Very nice, Well Done!!, the space between the top of the rear tire and the fender looks a little weird, how does it handle?

Gone 23rd December 2016 15:03

The bike of my dreams, wish it was mine.

84rzv500r 27th December 2016 00:34

150/80 on rear of xr1000... new wheels tires and brakes
cause i needed new rubber and I had the wheels/tires/brakes leftover from another project

150/80 K591S rear on 16x3.5 DNA Rim
100/90 K591S front on 19z2.15 DNA rim
H-D (sunstar) semi floating rotors all round

also solid mounts for the bar risers... much better

front is bolt on
rear needs the funky xr-1000 captured seal/spacers replaced with std 1.25x0.75 bits
you also need to make a new wire lower chain guard or go without (i will bend one up and mount it to the swing arm spool rather than the axle

you will have to follow the link to see pics as I am not allowed to post pics..

IXL2Relax 27th December 2016 03:05


Originally Posted by 84rzv500r (Post 5480867)
you will have to follow the link to see pics as I am not allowed to post pics..

No permission required to post pics - but you do need to HOST the pictures on another pic site (photobucket, etc.), then insert the [IMG] code into your posting here...

Or, track down the address of your pictures hosted on the Google site and use the Picture Icon here to create the [IMG] code you need... Like this:

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An XLForum collection of technical info & advice

84rzv500r 27th December 2016 23:59


Originally Posted by CT XR rider (Post 5479450)
Very nice, Well Done!!, the space between the top of the rear tire and the fender looks a little weird, how does it handle?

well its filled with a meaty 150/80 K591S now

very good.. raise the tail and drop the nose... flattracked from 1969 till 1975 then roadraced from 1983-2011

84rzv500r 28th December 2016 00:11

XR 1000 pics updated -- thanks for the help

IXL2Relax 28th December 2016 01:26

These might be helpful:

>>>> Build & Ride Reports Are Here <<<<

Reference the Sportsterpedia
An XLForum collection of technical info & advice

84rzv500r 31st October 2020 03:21

XR1000 Sport conversion to XR1000R Street Tracker
My XR1000(S) pictured above was spanked by hurricane IRMA in September of 2017... finally getting around to putting it back on the road... as you see above I had switched to meaty rubber/spoked wheels and 1999 XL1200S shocks and forks... and all was good then the cat 4/5 hit with a 10 foot tall wall of salt water... but since it is no longer a pristeen collectors Item I decided to enter the next phase... I have 2010-2014 XL1200 performance suspension option front ends and shocks... one set used off a 2010 and one new from XL1200X parts and BRAND new set Im gonna run the XR1200 calipers front and rear on 11.5" full floating disks... XR750 steel tank (Steve wants like 1300 for an aluminum one). stock XR1000 seat, and aluminum tsunami bobber fender. I picked up a pair of new XR1000 front rims and will run 100/90-19 Dunlop K180 front (for now but prolly switch to a 130 and a 140/80-19 K180 Rear. Chain tensioner to accommodate the swing arm angle change with 14 inch shocks.. drop a tooth or 2 on the countershaft sprocket :tour:D

dont worry all the very nice original parts are bagged tagged and corrosion proofed and stored above the water line... Stay tuned for PICS... having trouble deciding on a color... stock or harley orange and black?????????

84rzv500r 6th November 2020 00:28

4 Attachment(s)
new parts started showing up for this too... xr750 tank, alloy rear fender, shocks, forks, new 83 xr-1000 wheels, front to rear conversion kit, floating brake button Kit... oh and K180 dunlops... and a 2014 sportster rear brake carrier and caliper, oh and the XR1200 front calipers... no front fender on this project, prolly just thro a set of slider protectors on it..

84rzv500r 8th November 2020 22:16

more work waiting for the TS Eta
2 Attachment(s)
got the wheels all together got the 19 inch front to rear conversion done ! waiting for valve stems and front disk spacers from vulcan... I also decided to ge with a 130/80-19 K180A for the front as the 100 looked too skiny in the XR1200 forks and the 140 fits so the 130 should be fine...

84rzv500r 10th November 2020 15:44

3/4 wheel to 25mm axle problem
quick update... Looks like I have two solutions to the Timken 9052 3/4 bearing to 25mm axle problem...
solution 0: turn down the XR1200 axles to 0.748 (not enough material) :frownthre

solution 1: custom axle(s), kinda expensive... :doh

solution 2: turn down some 6061-T6 2" OD 1.5" ID tube stock to a light press fit 1.781" OD 1.575" ID 0.205" wall 0.700" long 6061-T6 sleeves and press into wheel bearing race bore, this converts the old style wheel to accept 25x40x17mm bearings and 35x45x7 mm seals. then turn down some 6061-T6 1.5" OD 1.0" id to 1.378 OD and cut to length, and make s bearing spacer out of 1.125x1.0 6061-T6, shim/fit if/as req :banana

bearings seals and tube stock on order :clap

now if beach barbie will just let me put the XR-1000 and XL 1200 wheels in the oven on warm for a couple hours :dunno

84rzv500r 11th November 2020 14:36

more parts...
4 Attachment(s)
Parts are rolling in...
I guess I should update H_D that their fitment list is a little lacking as im pretty sure these are going on a 1983 XR-1000 and 1999 XL1200 S :D

harley506d 11th November 2020 14:50

Are these sort any good for you?

84rzv500r 11th November 2020 16:23

Thanks yes I saw those however its the wrong direction in axle diameter...

I couldn't find a 1.781" x 0.984" bearing so Im going metric :D...

I'm gonna run the 25mm Xr1200 Axle on the front with 1983/84 XR wheels on my XR-1000 so rather than getting three new axles made (one for each bike plus a spare ) i decided to sleeve the wheels to use 25mmx40mm bearings and just make some sleeves and spacers and use off the shelf bearings and 35x45x7 seals. the axles are far more complicated and expensive to machine than just turning down some round aluminum stock to the correct dimensions and cutting to length...

From all my projects and racing i've learned that when ever i go to the trouble of making something don't just make one make a few for spares cause shit happens... :doh

harley506d 11th November 2020 19:36

Ah, sorry, i understand what you are doing now. Best of luck!.

84rzv500r 13th November 2020 17:05

no worries...

84rzv500r 13th November 2020 20:53

timken to 25mm problem solved... parts arrived
4 Attachment(s)
ok here are the pics... I have a little lathe work for the sleeves and the inner and outer axle spacers yet to go but its nothing fancy. Bearings, seals and shims were off the shelf industrial parts.. found a bearing company that was willing to make a run of 1.781 OD to 25mm ID bearings if I would commit to a 1000 units LOL :banadanc

Rear wheel ready for Rotor and PBI 52T alloy rear sprocket, stainless arp sprocket bolts drilled for safety wire....

Lip seals arriving Monday

84rzv500r 16th November 2020 17:27

one sorry XR-1000 thank you Irma...
2 Attachment(s)
So today started the cleanup and disassembly of a once proud scoot.. She is in sad state... the only thing that might be worse is what Irma did to my 8.2 litre injected 6 speed wide body 71 corvette...

Never fear they will both live again to annoy the neighbors :laugh

the good news is I will have 2 sets of 99 XL1200S forks/triples and Shocks to get rid of... :rolleyes:

CT XR rider 17th November 2020 14:57

Wow...what a sad event for your beautiful XR1000 and your Corvette. the pictures you posted at the beginning of this thread, back in 2016 shows a great looking XR1000, I know you will be able to get her back to her former glory, take your time and do it right, both vehicles deserve to be restored.
by the way, in addition to my XR1000, I also have a 1972 LT-1 Corvette, so I know how you feel if anything bad were to happen to either one of those.
Good Luck, and keep us posted on your progress

84rzv500r 18th November 2020 18:19

deconstruction progress...
3 Attachment(s)
sad yet happy pulling things down and packing them away...

ChinCactus 18th November 2020 23:12


Originally Posted by 84rzv500r (Post 5861468)
sad yet happy pulling things down and packing them away...

Nice! Start a build thread.

84rzv500r 20th November 2020 17:00

more deconstruction progress...
3 Attachment(s)
so Ive discovered a harley is all about order of operations and who ever was in their engineering dept had a sadistic yet twisted definition of maintainability :doh yet somehow so cool.... :wonderlan

84rzv500r 20th November 2020 22:02

i couldn't help it...
4 Attachment(s)
i just had to see if il looked like it did in my mind...

CT XR rider 21st November 2020 13:45

is that front end off a XR1200?, looks like it will work

84rzv500r 21st November 2020 14:53

Yep XR1200...
Bolts right up... I have the 25mm axle to 3/4 wheel all worked out as well as the hub width... harley, GM, and yamaha are all "Parts Bin" companies... makes updates and conversions to newer generation components WAY easier...:cheers

ChinCactus 21st November 2020 18:49

Quite a beefy front end. Looks great!

84rzv500r 22nd November 2020 00:20

more work...
test fitting and gathering /prepping parts.... Fitted the rear shocks... gotta widen the swingarm shock bracket a bit... maybe fab up some pieces that look like XR750 and are adjustable??

also salvaged the rotors off the old spoked wheels... the rotors are stainless so the salt water didn't bother them bit... however the rotor bolts were another story... out of 15 bolts there 2 that came out with heat... the rest were just breaking made in usa torx impact sockets so i drilled then all out...

then I ground the rivets out of the front rotors and installed a full floater kit... Jingel Jangel...

84rzv500r 23rd November 2020 19:47

test fitting...
some more test fitting...

Im not married to the seat and rear fender yet... if i use them i think i would cut some foam out of the seat and lower the rear of the fender a bit to match the curve of the wheel thats just where the bolt holes lined up.... I still might just go with a tracker tail....

Old Junk 25th November 2020 01:38

You've got a gorgeous bike coming together. Great work!

84rzv500r 25th November 2020 03:29

slow day...
Not much progress today I did get the fender marked for holes where i wanted it.. the alloy rear fender is growing on me.... gonna go with the stock 83 color and decals on the new tank... i have a NOS petcock somewhere in my stash of goodies... I need to pull the trigger on a new wiring harness.... im rapidly blowing through my budget :frownthre

the question now becomes to frame loop or not to frame loop. I wasn't gonna go into the engine but E cams and 10.5 pistons has some allure.. :drinkbeer

Steve9 25th November 2020 11:11

That will be fine going up A1A!

84rzv500r 25th November 2020 17:18


Originally Posted by Steve9 (Post 5862690)
That will be fine going up A1A!

lol i spent some time on A1A and donald ross sunday mornings were a show... i spent some time in the acreage on avacado... im down in the lower keys now... just one road in or out... US1

84rzv500r 28th November 2020 01:06

made a couple of bearing spacers
so so to keep this project moving i made a couple of bearing spacers for the 19" front to rear conversion today... :geek So tomorrow I will set up the preload mount the rotor and PBI alloy sprocket and make the adapter for the 2014 rear caliper carrier... the caliper is a tiny 4 piston setup on a 260mm rotor so i have to make an adapter out to 11.5 to use my floating sunstar rotor... :headbang

84rzv500r 1st December 2020 04:38

i guess its back to baby steps...
Wow they're not giving away a 1" ball end mills these days are they? :doh
and i gotta turn it down to 1/2 half inch shank to get in to my R8... no pain no gain...

84rzv500r 3rd December 2020 22:57

rear fender polished..
I took a break from the real job at lunch and put a polish on my rear fender...
first i drilled all the mounting holes and deburred them....
it took three passed with the buffing wheel to get to the last pic. I'll do one more by hand... any more and you will start seeing the imperfections in the stamp job...

Steve9 5th December 2020 17:56


Originally Posted by 84rzv500r (Post 5862760)
lol i spent some time on A1A and donald ross sunday mornings were a show... i spent some time in the acreage on avacado... im down in the lower keys now... just one road in or out... US1

I'm on Persimmon, runs into Avocado about ten blocks down.

Juno Beach Cafe on Donald Ross-best breakfast in the county!

I remember the keys, had an Uncle was a lobsterman on Conch Key '60/70s. He left Miami. There was too much land around him

Not much down there then compared to now

84rzv500r 15th December 2020 20:56

Rear wheel coming together...
had to make a 3/4" arbor to do justice on the rear wheel spacers... bearing preload set up. spacers made.. lining up the rear chain side done... working on the brake rotor and caliper carrier... since im switching to a 2014 sportster 4 piston caliper and carrier I had to sleeve that down to 0.750" and now i have to mill the thickness about 0.200 to get lined up... oh and its a 260mm (10.2") inch rotor diameter so the decision of which rear rotor to run and/or mill a bracket to relocate the caliper for a 292mm (11.5") rotor... i cant find a rotor that looks like it belongs in 10.2" but the old 10" rear rotor looks promising or turning down a rear 11.5 rear that i have that matches the fronts... 16mm/650 thou is a long way :wonderlan

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