#196 SR400Custom Report
Originally, this SR400 was acquired through a private sale from an owner in Kobe, who was a car body shop owner and enjoyed customizing cars as a hobby. We received an order to bring in the vehicle and worked on various modifications, such as the “Rigid Line” bolt-on hardtail kit, customizing the rear area including changing to 16-inch rear wheels, reviewing and inspecting all areas of concern throughout the vehicle, maintenance, and rewiring the main harness. We renewed it as a cool and safe custom SR, while preserving the good quality of its original state.
(This is what it looked like when it was brought in)
(For the maintenance of the entire vehicle, click here)
(For the process of hardtailing and overall custom work, click here)
【Movie of kick-starting and driving】

【Movie of the right side of the vehicle】

【Movie of the left side of the vehicle】

Custom List
FrontHandlebars, F forks, headlights, etc.
【Front Fork】
“Front fork 7.5cm joint pair for SR400/500“
〇A high-quality stainless steel fork joint. It makes a small SR look balanced and large.
【Front Tire】
〇A street tire with a vertical groove design. It helps to lighten the handling that tends to become heavy when long forks are used. It is a small, rounded 3.00 size.
【Headlight】
“4.5-inch Bates Light Chrome General Purpose“
【Handle/Handle Area】
◯The handle area, such as the T-bar, is basically the same as when brought in, but it is finished with re-routing of each wire harness and greasing up the lever/throttle area.
● Attached to the less noticeable and easy-to-operate lower part of the stem.
“MOTOR ROCK Decompression lever“
A decompression lever directly attached to the engine to simplify the area around the handle.
【Front Blinker】
〇A classic among classics. A chopper-style blinker.
【Speedometer】
“Mechanical speedometer φ48mm [No trip 1:4] General purpose #General-purpose parts“
We moved the installation position to the front left of the gas tank to make it simpler and more visible.
CenterTank, oil tank, seat, step, muffler etc.
• The gasoline tank is as it was when brought in, a peanut tank with a light aging paint applied.
【Muffler】
◯The trumpet muffler that was installed when brought in. It is being used by modifying the mounting stay.
【Step】
“Mid-High Control Parkerized for SR400/500“
〇This step kit is essential for 2%ER’s custom, which makes your riding posture cool and extremely less tiring.
【Seat】
“Narrow Type Bates Replica Solo Seat/Pillion Pad Set in Black“
〇A narrow solo/pillion pad with a flat base. Despite being made of vinyl leather, it’s a seat with a good atmosphere. The spring input position and angle settings, as well as the pillion pad mounting position, are unique to 2%ER and are set to minimize fatigue.
“Welding nut non-through M8 2p“
〇Used on the frame side as a seat spring receiver.
【Electrical Equipment】
“SR400/500 Custom Electrical Plate #2%er Original #SR400/500“
〇All electrical components except for the CDI are consolidated at the rear of the engine crankcase. It is easily accessible from either side of the vehicle and has good maintainability. There is no need to reassemble even if you revert to the swing arm specification during vehicle inspection.
“IC blinker relay wide range specification“
〇A wide-range turn signal relay that can handle 1-150 watts and can be used without difficulty even with LED turn signals. It can also be used as a replacement for the original relay.
〇This is a battery-less kit that we manufacture in Japan.
“Custom Ignition Switch Weld On Kit General Purpose“
〇Easy to operate even while riding, it is welded and installed under the left side of the seat.
【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 line. You can revert to swing arm/rear shock specification when you need to change the style or for vehicle inspection.
【Rear Wheel】
“16″ Kit Steel Spoke SR400/500 Rear“
〇This is a kit that gives a powerful look with the same size as a typical Harley.
We removed a 5cm long hardtail kit from another company that didn’t align when brought in, and set up the ““Rigid Line” Bolt-On Hardtail Kit” around the rear. The vehicle size becomes 13cm long, and it becomes a full-fledged style that connects the stem and the rear axle in a straight line like the rigid frame of the old days. As the name suggests, the installation is by bolts/nuts, so you can easily change to a swingarm/rear shock specification when changing styles or at the time of vehicle inspection.
The rear wheel is equipped with the “16″ Kit Steel Spoke SR400/500 Rear” and fitted with double ribbon tires.
The rear fender is a classic flat fender with 〇 “Spalt Tail Lamp Polished Japanese Standard Number Size“. We reinforced it enough to withstand the weight of the sissy bar and slight vibrations, and supported it with a 6-point mount.
The sissy bar is made of stainless steel and is custom made. We made it a little longer to match the style.
【Other Rear Parts Used】
“Weld Tabs/Nuts” (used in large numbers for mounting rear fenders, sissy bars, and turn signals)
“Small Bullet Turn Signal Matte Black 4pcs SET General Purpose” “Rear sprocket SR400/500 428-56“,,,
※Parts Reference may show similar products or products with additional processing.