1981 Yamaha XT500 custom
Words: Mike Ryan. Photos: Roland Evans
Decisions, decisions, decisions. Building a custom bike is all about making decisions. Sometimes, the very act of committing to a custom build is a big enough decision in itself, especially when the bike is rare or historically significant. In the case of this bike, an ’80s-era Yamaha trailie, the decision was much easier.
XT Heritage
In Yamaha’s extensive history, it’s usually the track racers, sports bikes and mega-power models that get all the attention. Sure, the likes of the TZ 750, VMAX, OW-O1 and YZF R1 are worthy of kudos, but there’s just as much to be celebrated in Yamaha’s off-road range, like the XT600 Tenere, YZ 250 and 450, TDR 250, and the XT 500.
The XT 500 is pretty significant, actually - more than it’s given credit for, as it kickstarted the XT dynasty and the whole ‘Thumper’ genre of big four-stroke singles.
It’s often forgotten that the XT 500 was the original Dakar rally winner, too. Cyril Neveu won the first and second Paris to Dakar rallies on an XT500, and XTs filled the podium on the 1980 rally, but the dominance of the BMWs - and more recently KTMs - that followed means Yamaha’s trailblazing wins are often overlooked.
Launched in 1975 as what was essentially a road-legal version of the TT 500 motocrosser, the XT 500 found success in the US (its primary market) and Europe, as well as here in Australia.
The XT’s original two-valve head was replaced with a four-valve design in 1982, with capacity increased to 558cc to make the XT 550, followed by the XT 600 in 1984, but the original 499cc version is arguably the king of the Thumpers of this era, although Honda XL 500S and Suzuki DR 500 fans will probably disagree!
Beyond its Dakar heroics, what made the XT 500 a success was that it was such a fun bike to ride. A lot of Aussies have great memories of time spent on XTs and Roland Evans is one of them.
From Resto to Custom
A classic 1976 Kawasaki Z900 currently occupies Roland’s garage, but when he decided he wanted an off-roader to accompany it, there was really only one choice.
“I had an XT when I was a kid and loved it,” Roland recalled. “I knew how reliable and bombproof they were, so when I wanted a project, this seemed like a great choice.”
Searching online for a suitable bike, it wasn’t long before the Queenslander found what seemed like a strong candidate.
“I found an ’81 XT 500 – a one previous owner bike and true barn find from a farm in northern Queensland.”
Purchased unseen, Roland’s plan was to restore the bike to its original condition, or at least good running order, but that changed when his new purchase arrived.
“When I got it delivered, the bike proved to be well past it, so I decided we would have some fun with it instead.”
The path was now to make a customised XT, so the bike was sent to Bike Tech in Nerang, (Queensland), for the modification and fabrication work that was to follow.
The first job was a full rebuild of the 499cc four-stroke single, with a new piston and new valves, but the capacity and basic specs remained standard. The exception was the exhaust system, which was replaced with a custom header and Akrapovic silencer.
Similarly, the XT 500’s standard 5-speed gearbox was rebuilt, with replacement parts added as required, but the gearing and sprockets were kept in stock spec.
Holding everything together is the stock XT 500 frame that was completely stripped, cleaned and powdercoated in black, with the engine painted to match, but XT 500 fans will know that this is how they came from the factory, so no major change there.
What did get a major change was the electrical system. Roland decided an upgrade was needed here, so the bike now runs a 12-volt battery and compatible wiring loom, with all-new lighting fitted at each end, including a cool, retro-look dual tail light.
Suzi and Style
That lighting upgrade was part of a style makeover that saw the front end replaced with forks and triple trees from a Suzuki GS 500 that also donated its front mudguard to the project.
The handlebar retains an enduro look but is an aftermarket item in the style of a Renthal fat bar. To this, custom grips, levers and mirrors, as well as aftermarket master cylinders and switchgear, have been fitted.
An Acewell multi-function speedo replaces the twin factory clocks and is a neat match to that aftermarket headlight with its retro-look stone guard.
The fuel tank and side covers are the factory Yamaha units, but fully refurbished and repainted to give them an all-new look, with the bare metal sides of the tank adding to this creation’s retro vibe.
That old school approach continues with the seat, which has been shortened and restitched, with a red diamond pattern on top to pick up on the plastics.
While the tank and sidecovers remain unchanged, that non-standard front end blurs this bike’s origins; an effect enhanced by the custom wheels and road-spec sports tyres.
The wheels are made up of Excel Takasago rims with stainless steel spokes on Yamaha YZ450F hubs. The black anodised finish of the rims and hubs picks up on the treatment of the frame and engine, keeping the whole thing aesthetically balanced. Tyres are 17 inchers from Dunlop – Arrowmax on the front and Rideen on the rear.
On the brakes, there’s plenty of stopping power now, thanks to aftermarket supermotard-style discs with two-piston calipers at each end - certainly an upgrade from the factory drums that were a known weak point on the XT 500 when it was new.
Finally, to suit the new rear wheel and brake package, Roland had Bike Tech fit a Kedo aftermarket swingarm and all-new rear shocks.
Six and Out
All up, the project took six months to complete, and Roland’s pretty happy with what was achieved in that short period, but says praise should really go to Bike Tech, specifically Linton Gross.
“Linton did the work – I just sourced parts…and provided the capital!” Roland laughed.
Given he spends a lot of time overseas, Roland rarely gets to ride this creation, which is one reason behind his decision to put it on the market (see breakout). The other reason is that he’s keen to take on a new project!
Looking at this build, there’s a lot to like about it, and everyone who sees it is sure to have a favourite feature, but what does Roland like?
“The colour scheme and the brightwork are great, but for me, it’s all the small details that really make a difference and make this bike special.”
One thing’s for sure – what started as a blind purchase has turned out to be a feast for the eyes.
FOR SALE
Now he’s got the custom bike bug, Roland is lining up his next project, so this one’s for sale.
Since the build was completed in late-2016, the bike’s covered minimal kilometres, so all the custom parts and features are still very fresh. Those minimal kms also mean the new owner needs to do nothing more than jump on and enjoy the ride.
Asking price of $14,995 includes nine months full registration for a Queensland buyer.
Contact Roland for more details on 0433 335 597.
View the ad online at justbikes.com.au with the ad code JBW5046012.
