Yamaha SR500 Cafe Project more fun and fabrication 

If anybody is having trouble finding rear brake master cylinder hydraulic seals for the early SRs or XS 400s with rear disc brakes try early 1980s Harley Davison seals. (1978/84?) The Harley piston won't work but the "5/8th" seals appear to be the same as the "5/8th" Yamaha seals. The Harley spring is longer but if the Yamaha one was to corroded to reuse you could probably cut the Harley one down to suit. And the Harley C clip is the same as the Yamaha one. I cut the Harley piston in half with a hacksaw to get the hollow seal off without having to stretch it unnecessarily. I cleaner up the SR piston as best as I could and reused it. From memory I was able to fit the outer end in a drill and spun it while using needle files on the low corroded places and fine sandpaper to clean around it higher surfaces where it slides in the cylinder. Be very careful not to disturb the fine metal petals on the inner end of the piston. The Yamaha external rubber dust cover had bloated and grown larger through years of exposure to leaking hydraulic fluid so I put a fat rubber O ring in the groove that supposed to keep the dust seal in place and fitted the retaining lip of the dust cover over the O ring. You could also use a cable tie around it to retain it or maybe use both if it has become really loose. I also painted the places on the outer end of the piston not exposed to fluid and the metal rode that pushes against the piston to help prevent it from rusting.

mechanic, metalworker, leadroll, director, and producer......your a multi-tasker!

So I have been unfortunate to be able to learn things mechanically at a young age but always loved custom fabrication. Lately I have been thinking of taking some classes in metal working/welding. Well, this video just finally convinced me to go do what I have always wanted to do. AWESOME.

Like a GP500 the SR500 was one of the best looking FACTORY STOCK bikes to come out of Japan.Unless it was a piece of junk it would be awful "cafe" it.

I'm considering taking on a project like this. Holy fuck I have no chance. You've got talent man.

SR500: wonderful bike... great handling.. only 29 BHP stock, but excellent on windy roads....

That is the coolest idea for an egnition I have ever seen. What I would do next is on the other plug, put a LED single digit display so it shows what gear you're in.

I regretted selling my sr500 about 6 years ago and after watching your videos I'm really KICKING myself! Great stuff by the way!

Thanks fans! Were working on a CNC aluminum version of the sprocket guard, hopefully available soon for sale on our website. So keep checking the site for updates if anyone is interested. May also be producing tachometer plugs and triple plugs and accessories. time will tell...

Awesome job! If my Yamaha TX500 76 project achieve 20% of that state of art of yours, I will be glad! Sorry abou my poor english... Im brazilian! Very inspiring! Thanx for share!

Great creativity on that ignition...really bad ass

Parabéns pelo seu trabalho, Deus abençoe você !

Looks good so far ! Very precise working my friend ;) I have an SR 250 from 82... And really would like to make it cafe racer style...

Wow, mad skills!

DUDE! I'm am so impressed. You are a very skilled machinist. You have quite the workshop! I LOVE that color frame. I saw your last video when you powder coated it. Gun Metal Grey - I think it was. My next build will have a frame that color. That bike is looking SO SICK! Is this a build for you or a customer?

Why not drill and tap the ignition part in the lathe? Nice job still :)

looking good as your work always is watching this build

Amazing bike, amazing tunes, amazing video ... thanks ... two thumbs up!

Any ideas for fitting an after market race seat to a 1983 sr 500? I was thinking to use some kind of bracket that screws into new seat and in other end into current mount bolts for current seat

Nice video...trying to capture all your work on film makes the job twice as hard.

Hi I wonder if you can advise me on registering a custom bike? I just purchased a new Mash Cafe Racer 125cc in Italy. I have to return to the states and cannot import my bike because it doesn't have the required DOT and EPA papers for importing. My plan was to disassemble my bike and take all my parts back to the states, (except the motor and frame). Would it be easier to put all my parts on another bike and re-register, or should I buy a new motor and new frame and then try to register it as a custom bike? I have never done this before and don't know how hard it is to register a custom built bike. I really don't want to buy an old bike and throw my new parts on, and I don't want to buy a new bike and put my parts on and waste money. (Obviously I could sell my bike here, but I love my bike and want to try to save what I can to keep it's integrity).

simply awesome ! Impressive craftsmanship....grats.

Very nice job man! 8 enviers!

hello sir may i ask for information about the song you use

Hei Chris, nice job. Fantastic. congratulations!!

Nice bike! Which footrests did you use?

Nice Garage!

you made look pro Bro

Loving your work mate, simple, elegant and cool as f**k!

First reveal of the bike is out now! check description for links!

Great skills bro.

日本で言う機械屋さん、いい腕の職人だね。nise

It seems so easy !!!!

very nice!

omg sick shop, sick skillsss!

what the song title on 4.18, anyone know?

Peeerrrfect.Nice. Keep up the good work.

great job man .

Fantastic work.

muy buen vídeo amigo

perfect video.

Man i love your shop brother .. I would love to see a Shop Tour .. I gave you a sub and put you on my fast updates .. I like your work very much Gbu

good job!!

sick music.

Thumps up!

You are an amazing artist! cheeeers

Very good!!!!!

amazing!

โคตรเก่งเลยวะผมก็ชอบsrเหมือนกัน

I am from indonesia

except rule continuing severe store exclude.

my IDOL

Hi

สุดยอดวิชาเลย

Dis 'popcorn' you spik uf....vil it bee in dee lobbee???

don't powdercoat this please the aluminium looks so nice

man's romantic!!!

Hi