#157 SR500Custom Report
“We received an order to create a unique chopper that would suit both a ‘German helmet’ and the ‘MTX Helmet’ from Ocean Beetle. The chopper is based on the SR500.
We created it in a unique style, adding a balanced amount of elements from scrambler and sand race styles to the base old school chopper style, without overdoing it.
In the rear section, we incorporated the ‘Rigid Line Bolt-On Hardtail Kit’, creating a rigid frame without rear shocks. However, by carefully designing the choice of seat, spring input, and angles, we have achieved a comfortable ride that doesn’t feel like a rigid. You can ride long distances without getting tired. (We also joined a summer tour in Hokkaido in 2017)
This custom was created in two weeks from the ‘original form’ in order to make it in time for this tour.
Since it was a rush job, the paint was applied with a brush, leaving brush marks. The regular owner and I painted it together to prevent it from becoming too clean. The more you ride, the more dirt and flavor will appear on the brush marks.
【Detailed explanation, introduction video】

【Driving video】



(This is an interview movie from Chopper Journal)

2017 Hokkaido Touring (We joined around 8 minutes and 15 seconds)


Custom List
FrontHandlebars, F forks, headlights, etc.
【Around the Front Fork】
“2%er 10cm long Joints for Front Fork (pair) [SR400/500]“
〇High-quality stainless steel fork joint.
“SR400/500 15cm long inner tube kit“
〇A fork tube kit that allows you to extend the front more safely.
“2%er Tweak Bar (front stabilizer) [SR 400/500]“
〇A stabilizer that is extremely effective in correcting the handling that tends to lag one beat behind with the extended fork.
“Welding Side Stand Extension Plate”
〇A plate for extending the side stand that leans too much when the fork is extended. Welding is required.
【Front Wheel】
“H-shape aluminum rim SR Front, one size up“
◯Select off-road tires.
“2%er Front Wheel Aluminum Hub Cap [SR400/500]“
〇You can change to a classical style by sticking it on a normal drum brake.
【Headlight】
“5.75 inch Bates Light Chrome General Purpose“
〇A selection that allows you to run without worry during touring, with brightness, safety, and good maintenance, without relying on vintage parts.
〇It’s a standard headlight, light stay.
【Handle, Around the Handle】
◯ The replica windshield from the 1940s, “HWZN Jack Tracy,” is used as an accent.
◯ The handle is a stainless conch handle that was lying around in the shop.
“Flanders Replica Riser/Shorty SR400/500“
◯ A Flanders replica riser with a great atmosphere. Mounted in an easy-to-operate position.
“SR400/500 Handlepost Offset Collar“
◯ The normal handle post can be moved forward and backward. The mounting width has been changed to a narrower size.
“Amal type throttle holder, general purpose (for 7/8″)“
◯ The controls have been minimized and cleaned up with mini switches, etc., and the removal of the clutch lever due to the jockey shift has made it even simpler.
“MOTOR ROCK Decompression lever“
A decompression lever directly attached to the engine to simplify the area around the handle. (The one on the vehicle is an old model)
【Front Blinker】
“Small Bullet Turn Signal Chrome 4pcs SET General Purpose“
〇A classic among classics. A chopper-style blinker.
“SR400/500 Bottom Mount narrow blinker stay“
〇A stay to attach a 10mm blinker to the bottom of the frame.
【Speedometer】
“Mechanical Speedometer 60mm Black Panel 1:4“
〇Mounted on the left front side of the gasoline tank, where it is inconspicuous and highly visible.
CenterTank, oil tank, seat, step, muffler etc.
【Muffler】
“Exhaust Pipe Flange Set for One-off Pipe Production”
〇A one-off side exit using a convenient production kit for the root mouthpiece. The heat shield of the Suzuki/Bang Bang 50 was used as an accent.
【Step/Shift】
『Mid-High Jockey Shift Kit Chrome for SR400/500』
〇Maintaining the comfortable riding posture of the mid-high step, this is a jockey shift kit that focuses on operation feel such as touch and stroke.
【Carburetor】
“FCR carburetor 39φ SR400/500 single unit“
〇The slow SR will drastically change. It is a high-performance carburetor with sharp and smooth acceleration and good startability.
〇It is a dedicated adapter to firmly fix the FCR carburetor to SR400/500.
“Net funnel set for FCR carburetor“
〇It is a set of a change from a red plastic funnel to aluminum, and a stainless steel debris net.
【Seat】
『 BATES Type Solo/Pillion Set White』
〇A seat set with good cushioning made of genuine leather. The spring input position and angle settings, as well as the pillion pad mounting position, are set up in a fatigue-resistant manner unique to 2%ER.
『Welding nut non-through M8 2p』
〇Used by welding to the frame side as a seat spring receiver.
【Electrical】
“SR400/500 Custom Electrical Plate #2%er Original #SR400/500“
〇All electrical components except the CDI are consolidated at the rear of the engine crankcase. It is easy to access with both hands from either side of the vehicle, and there is no need to reassemble even if you return to the swing arm specification during vehicle inspection.
〇This is a battery-less kit made entirely in Japan.
“IC blinker relay wide range specification“
〇A wide-range turn signal relay that can be used without difficulty even with LED turn signals, compatible with 1-150 watts. It can also be used as a replacement for the original relay.
“Custom Ignition Switch Weld On Kit General Purpose“
〇The main key, which is originally attached to the top bridge, is welded and installed under the seat on the left for easy operation even while riding.
【Kick Pedal】
“Drilled Kick Pedal HWZN Aluminum“
◯It has a larger surface area than the standard kick pedal, making it easier to kick.
【Gasoline Tank Installation】
“Sportster Tank”
“Welding nut non-through M8 2p“
〇Drill a hole in the gasoline tank body and insert and weld. It’s non-penetrating, so it won’t leak. Used on both sides.
“Weld tab M size 4.5mm thickness 2p“
〇Enlarge the hole diameter and change to a rubber mount specification to hold the non-penetrating nut. Used on both sides.
“Weld tab L size 4.5mm thick steel 2p“
〇Used for the rear installation of the gas tank. This also enlarges the hole diameter and uses it as a rubber mount.
【Engine Area】
〇A filter kit needed when removing the original air cleaner.
“2%er Fin Tappet Cover (a pair)[SR400/500]“
◯A tappet cover with a heat-dissipating fin design that serves as an accent. It is forged from high-quality aluminum and carefully buffed to a mirror finish.
【Drive System】
“Front sprocket SR400/500 428-19“
〇A durable replacement sprocket made of steel.
RearFenders, rear shocks, swingarms, etc.
【Hardtail】
『“Rigid Line” Bolt-On Hardtail Kit』(13cm long, made to order)
〇As the name suggests, this is a detachable hardtail kit using bolts/nuts. It remodels the seat rail of the original frame to make it rigid. You can revert to the swing arm/rear shock specification when you need to pass an inspection or change the style.
【Rear Wheel】
“16″ Kit Steel Spoke SR400/500 Rear“
〇A kit that gives a powerful look with the same size as a typical Harley. The tire is ALL STATE Dirtman.
“Drilled plate torque rod SR400/500“
〇This is a drilled design torque rod to avoid interference with the wider tires.
【Rear Fender/Sissy Bar】
◯A universal flat fender. It is reinforced with suitable materials on the back to withstand the weight and vibration of the luggage tied to the sissy bar, and for use in long touring. Following the style of sand racers and scramblers, the rear fender is mounted a little off the ground.
◯The sissy bar is a one-off production of the spade type from that time.
【Tail Lamp】
◯Designed in the style of an old-school chopper.
【Turn Signal】
“Small Bullet Turn Signal Chrome 4pcs SET General Purpose“
〇A classic among classics. A chopper-style turn signal.
“Weld tab S size 4.5mm thick steel 2p“
〇Welded onto a hardtail. Used as a base for the turn signal.
【Drive System】
『Rear sprocket SR400/500 428-56 』
〇An affordable and durable replacement sprocket.
※Parts Reference may show similar products or products with additional processing.