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Thread: 1982 XR500R Dual Sport Trike Build

  1. #1
    Join Date
    Nov 2021
    Location
    Washington
    --
    5

    1982 XR500R Dual Sport Trike Build

    I want to share my 1982 XR500R trike conversion with everyone. I'm in the middle of converting this old 4 stroke thumper into the trike that Honda could have made, but didn't. And it will be fully street legal.


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    I started out by fitting the stock seat pan to a 1985 ATC250r new plastic rear fender. I also recovered the seat. The seat and rear plastic and now one unit and secures using the stock mounts. I put a star shaped nuts on the rear bolts to be able to loosen them up by hand. This bike is kick start only. And because it's a motorcycle, it kicks to the back, not the front. I will have to remove the seat every time to crank it. Just one of the oddities of a conversion. But it works well.

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    The rear swing arm is from a 1988 TRX250r that has been machined to fit into the frame and also I had to put in 20mm bearings, not the 30mm that is stock. The rear suspension linkage and shock is a OEM new take off from a 2005 TRX450R. I had to fab and weld in the mounts and supports for the rear suspension. I also extended the frame by 3 inches. Its just tacked in right now. And no, I am not a pro. But I will get those gaps welded up.

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    My street tires are DOT radials. My front wheel will be a modified goldwing wheel to be a direct replacement for the 1985 ATC250R stock wheel. They use the same size diameter axle, but needs custom spacers to work. I will post pics later. The front forks are 1985 ATC250R, but are not on the bike yet. I am still building the trike, and will be tearing this down to the frame to paint before messing with the front forks. I am rebuilding the forks and adding new springs before it goes on.

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    I will post more pics as I make progress.
    Last edited by XR500R Trike; 11-06-2021 at 12:23 AM.

  2. #2
    Join Date
    Apr 2014
    Location
    Edmond, KS
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    2,274
    Very nice project. It's ironic because I have a 1982 XR500 that is probably going to be my next project. I will be keeping it with only two wheels though.

  3. #3
    Join Date
    Jan 2009
    Location
    ohio
    --
    1,659
    Keep up the good work. Keep us in the loop. There was a thread on here were someone converted a xr 500 to a trike
    If its on the internet its got to be true they can't put any lie's on the internet

  4. #4
    Join Date
    Nov 2021
    Location
    Washington
    --
    5
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    Thanks for the interest. I got the canister type oil cooler and remote oil filter tacked on. The Xr500r frame is taller then an ATC or TRX frame. This gives me plenty of clearance for the oil filter to be mounted between where I will build the battery box and the storage box. I'm using a plastic ammo can for the storage. Fits perfect.

  5. #5
    Join Date
    Feb 2021
    Location
    Upstate NY
    --
    6
    Looks great so far!...

    I did a similar build with a KLR650 last year.

    I see you are sticking with the stock triples...I used Harley wide glide triple clamps with the stock Kawi forks and a ZZR600 rear rim in front.

    Lots of mock-up to see what fits where...I know your pain, but it's worth it!

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    Enjoy!
    LT

  6. #6
    Join Date
    Apr 2019
    Location
    South Dakota
    --
    154
    Cool project. I have an xr350 that i have though about doing this too, but time and money are the things i need but dont have! Cant wait to see how it turns out.
    Currently : atc200m, trx400, xr350r, xl250s, yz250
    Gone: 200es, yt125(x2) 250es (x5), 200e, 200m

  7. #7
    Join Date
    Nov 2021
    Location
    Washington
    --
    5
    Quote Originally Posted by judge1111 View Post
    Looks great so far!...

    I did a similar build with a KLR650 last year.

    I see you are sticking with the stock triples...I used Harley wide glide triple clamps with the stock Kawi forks and a ZZR600 rear rim in front.

    Lots of mock-up to see what fits where...I know your pain, but it's worth it!

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    Enjoy!
    LT
    Quote Originally Posted by judge1111 View Post
    Looks great so far!...

    I did a similar build with a KLR650 last year.

    I see you are sticking with the stock triples...I used Harley wide glide triple clamps with the stock Kawi forks and a ZZR600 rear rim in front.

    Lots of mock-up to see what fits where...I know your pain, but it's worth it!

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    Enjoy!
    LT
    Thanks man. I love your solution for the front end. Trying to figure out the front tire was challenging. I went with OEM 1985 forks, triple tree to save time. Definitely not money. Judging by the prices I thought they would be gold plated. Trying to figure out a DOT radial to fit with the forks was a challenge. I wasn't happy with the choices which is why I started thinking of using a fat motorcycle tire and modified wheel instead. You must have had similar concerns. Your trike looks great. I wish I had electric start.

  8. #8
    Join Date
    Nov 2021
    Location
    Washington
    --
    5
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    I got the frame all welded up. The battery box is built out of 1/8 inch steel and welded into place. It also doubles as a frame brace. I cut off anything I didn't need. And got two coats of Rust-Oleum self etching primer on.

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    I got the first coat of gloss black. I'm using VHT engine enamel for this. I think this will stay on pretty good.

  9. #9
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    2,885
    Looking great so far, watching this one for sure! Is that a wood stove in your paint booth?
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Resto Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  10. #10
    Join Date
    Nov 2021
    Location
    Washington
    --
    5
    Yes, that's a wood stove. When I paint anything, I will open both ends of the "paint booth" to get the fumes out before I use the stove. I put a duralog in there and it will heat the "paint booth" up in about 10 mins. Not ideal, but it works.

    Also, I have a update. I didn't like the top coat so I dropped off the frame to the powder coater. The VHT enamel seemed to want to chip a little to easy for my taste. Should have done this in the first place. I'm using VHT caliper paint on some aluminum wheels for my Jeep, and it is not chipping. Live and learn.

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