Home » #257 SR400

#257 SR400

2022.8.17

Custom Bike

#257 SR400Custom Report

The request came from an owner who has been associated with the custom shop “CHUCK BOX”, where the 2%ER owner first started training, CHUCK BOX. The order was for a change from the aging cafe racer style, which we had previously worked on in various parts, to a clean hardtail bobber.

The light stays and handlebars were processed from Chuck Box products that had been installed previously, and we created a unique style while incorporating the owner’s requests, such as a 13cm long hardtail, a narrow gas tank with original processing, a new fork outer spring kit, a left-up exhaust, and a rear fender that is far from the tire, while maintaining the overall balance. It is a fully customized vehicle with almost everything from wheels to frames and carburetors.

The ride comfort has improved dramatically compared to the cafe style. The seat is designed with a hardness that does not bottom out with the weight of a typical Japanese male, and is set in a position that is remarkably resistant to fatigue with a mid-high step.

A sub-bottle of gasoline is installed under the seat.

The frame, which has a faint blue-gray metallic fade, and the paint of the exterior parts, which have a gunmetallic gradient, were left to “JERK GARAGE”, a long-time acquaintance of both the vehicle owner and the 2%ER owner. JERK GARAGE. We had a lot of discussions with the owner and had them painted.

The rear fender stay is made in two types to match the style and purpose. Normally it is a brace without height (as in this custom gallery), but for long touring, it can be bolted on to a sissy bar where you can tie your luggage.

(Appearance at the start of customization)

【The sample car based on the STD Hardtail Complete is here】

【Over 70 examples of Hardtail production are here】

【Driving Video】

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“This is the vehicle scheduled to be exhibited at the New Order Chopper Show in Kobe on 8/21“

Custom List

FrontHandlebars, F forks, headlights, etc.

●The front area is uniquely styled with a separate handlebar cut to a length and narrowed to a full width of 45cm, a new fork outer spring kit, and a deliberately chosen 7-inch diameter headlight for a slim body.

【Front Wheel】

“H-Type Aluminum Rim Front One Size Up (2.15-18)”

〇A high-end H-section aluminum rim often used as the finishing touch on everything from racers to choppers. It changes from the standard 1.85 width to a 2.15 width.

“Starburst Hub Cap”

〇An aluminum polished finish hub cap that is easy to attach to the drum hub.

“Pirelli MT53 Replica 4.00-18”

〇A replica of the 70’s Pirelli. It suits all styles, from street to tracker, scrambler, bobber, chopper, and more.

【Front Fork】

“Fork Outer Assist Spring Kit For SR400/500“

〇Assists the sinking of the fork that is too soft with a classical external spring kit.

“Bottom Case”

〇Stay parts are smoothed and finished with buff polish.

【Headlight】

“Lucas Type Headlight Case”

〇A standard 7-inch diameter, bullet-shaped headlight case for cafe racer style. (Without ammeter, painted)

“Lucas Torch Headlight Lens H4”

〇An extremely classic round top lens with an old Lucas logo. It is an H4 bulb specification.

“CHUCK BOX High Mount Pipe Work Light Stay”

〇A handmade light stay made of stainless steel in the Rockers style. (The mounting position has been changed to mount it lower)

【Handle/Handle Area】

“CHUCK BOX Ace Bar Handle”

〇Extremely thick stainless steel, extremely simple handmade separate handle. (Use by cutting the length)

“Amal type throttle holder, general purpose (for 7/8″)“

〇A very simple classic vintage style throttle.

“Chopper Grip”

“Amal type slot wire 800mm ’88~’08“

“Brake wire/100mm 200mm 300mm 600mm SR400/500 #SR400/500“

“Clutch wire/300mm 200mm 100mm standard SR400/500 ALL YEARS“

“Aluminum Short Brake Lever/Holder Set“

“Aluminum Short Clutch Lever/Holder Set“

〇A compact and simple, easy-to-grip aluminum lever set.

“Handle Lock Weld On Kit“

〇It is newly installed by welding to the lower part of the stem, which is inconspicuous and easy to operate.

“MOTOR ROCK Decompression lever“

A decompression lever directly attached to the engine to simplify the area around the handle.

【Stem】

“2%er Top Bridge Ⅰ for separate handle [SR400/500]“

〇A classic style top bridge without holes for bar handles. (We have further simplified the meter stays with smoothing)

【Meter】

“Inside Meter Kit”

〇A meter kit that can be bolted on the inside of the fork when viewed from the front, specifically for small tanks.

【Front Blinker】

“Micro Blinker” (Discontinued ⇒ Now changed to Star Bean Blinkers, Set of 2, Black)

“Universal Blinker Stay 10A Type Steel”

〇The ultra-small micro blinker is installed on the front side of the lower engine mount.

【Classical Minus Bolt】

〇A round top screw, also known as a pan head. (Used for attaching things like headlights)

CenterTank, oil tank, seat, step, muffler etc.

● The increasingly popular genuine narrow-processed gasoline tank is safely mounted with three-point rubber. The frame under the seat is cut from the original part, and considering strength, accuracy, durability, and maintainability, it is rebuilt to match the angle of the “Hardtail Kit” at the rear. The step is mid-high to improve ride comfort, and the seat attachment is ingeniously designed. The bottle under the seat is a sub-tank for gasoline.

【Muffler】

“Left Up Exhaust Pipe“

〇A user-friendly 45φ diameter exhaust pipe, carefully crafted with attention to the line. (Painted in black for use)

“Universal Stainless Steel Trumpet Muffler“

〇A domestically produced stainless steel muffler with a 45φ insertion diameter. (Two are used by creating an intermediate pipe)

【Step】

“Drilled Mid-High Step Kit/Chrome”

〇A standard mid-high step with a drilled plate. The coolness of your riding posture and the reduction of fatigue will significantly improve.

【Seat】

“BATES Type Genuine Leather Solo Saddle Seat Vertical Tuck Roll Black/White“

〇A genuine leather solo saddle seat with a balanced price, look, and comfort. It is installed with a soft ride that is less likely to bottom out by changing the mounting angle and spring input position.

(Discontinued) ⇒Genuine Leather STD Solo Saddle Seat Black

“Solo Saddle Seat 2 Inch Spring Comfort Mount Set”

〇A mount kit that is easy to install on custom frames and the like. The lever ratio can also be changed, allowing for good cushioning.

【Carburetor】

“FCR carburetor 39φ SR400/500 single unit“

〇Your slow SR will drastically change. It’s a carburetor that’s easy to handle with sharp and smooth acceleration.

“Net funnel set for FCR carburetor“

〇This is a set of a stainless steel trash guard net and an aluminum funnel, which is a change from the red plastic funnel.

“Manifold Kit for FCR39φ”

〇This is a dedicated adapter to firmly fix the FCR carburetor to the SR400/500.

【Tank】

“Genuine Processed Gas Tank”

〇A gasoline tank based on a normal base narrowed to about 18cm in width.

“Weld tab L size 4.5mm thick steel 2p“

〇Used for attaching the rear part of the gas tank. The hole diameter is also enlarged and used with a rubber mantle.

“Emergency Sub Tank Kit”

〇A 1-liter sub-tank developed exclusively for SR400/500. (This time, a mounting bracket is made on the frame and installed under the seat)

【Electrical Equipment】

“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 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 any problems with LED turn signals. It can also be used as a replacement for the original relay.

“Battery Lesser“

〇This is a battery-less kit that we manufacture in Japan.

【Ignition】

“Custom Ignition Switch Bolt-On Kit”

〇This is a kit that allows you to attach a small ignition switch to your preferred position with an M6 bolt.

【Engine】

“Crankcase Cover”

〇Finished in black wrinkle paint.

“Breather filter SR400/500“

〇This is a filter kit needed when removing the original air cleaner.

【Drive System】

“Front sprocket SR400/500 428-19“

〇A durable replacement sprocket made of steel.

RearFenders, rear shocks, swingarms, etc.

●A simple rear area without a sissy bar, featuring a hardtail kit (13cm long) that determines the overall styling, and a sturdy steel rib fender.

【Rear Wheel】

“H-Type Aluminum Rim Rear One Size Up (2.50-18)”

〇A high-end H-section aluminum rim often used as the finishing touch on everything from racers to choppers. It changes from the original 2.15 width to a 2.50 width.

“Rear Drum Starburst Cover”

〇A classic polished aluminum accessory cover that simply fits over the rear brake panel.

“Pirelli MT53 Replica 4.00-18”

〇A replica of the 70s Pirelli. It suits all styles, from street to tracker, scrambler, bobber, chopper, and more.

【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 go for vehicle inspection or when you want to change the style.

【Rear Fender】

“5-Inch Custom Rib Fender – Steel Material“