Transition from MT500 to Project Scruffy - MT604e.

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green_machine

Transition from MT500 to Project Scruffy - MT604e.

Post by green_machine » Sat Jan 23, 2010 10:51 pm

Hi all,

About a year ago, after a couple of frantic text messages, a drive to Peterborough and an exchange of cash, I found myself with an ex CCM Dual Sport 604 engine. The initial idea was to transplant it into my MT350 in the same way Apophis had done his.

After a bit of thought, and Bunker saying at the Uttoxeter meet "nice bog standard 350 that" I decided to keep that bike the way it was:

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That left me with an engine and nothing to put it in! At the same time Digger had taken possession of a MT500 project bike from Bunker with the intention of getting it roadworthy for his brother to ride. He got it to the stage where it ran and didn`t really need much more time spending on it when the said brother started to lose interest.

After short negotiations and the proviso that he stored it for me while I convinced the girlfriend it was a good idea I found myself pushing it home. Only half a mile, but I was knackered when I got home.

Let me introduce Scruffy:

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The photo`s don`t do it justice - it`s a lot worse than it looks!

First job was to strip the bike down to it`s major lumps and get to work on the frame. I had a couple of pm`s with lowuk to get the general idea of what I had to achieve and then set to with the cutting disc and welding gear. Firstly modify the frame for the starter motor to fit:

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As per lowuk`s advice I sourced a MT350 front engine mount and modified the frame to suit:

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Next was the issue of fitting a larger battery. After much searching I settled on a battery destined for a Yamaha R1. It`s dimensions were just right, all I had to do was make it fit. The original mount was too low so I chopped it out and fitted a new one about 30mm higher along with a new battery tray:

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I then realised that the front engine guard wasn`t going to fit as I`d lost the upper mounting hole when I modified the frame:

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I decided in the end to mount the primary filter on the frame behind the kick start, very pleased with how it turned out:

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There`s a bit more work to be done to tidy the frame up and repair little bits and pieces and then it`s off to the powder coaters. While it`s away I aim to get the engine serviced and painted, the wheels sorted out and order any parts I shall need to get the rolling chassis back together.

So far so good but slow progress.......... :|

Stuart
Last edited by green_machine on Sat Jan 23, 2010 11:17 pm, edited 1 time in total.
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TDIPower
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by TDIPower » Sat Jan 23, 2010 11:08 pm

looking great!!!

Pete
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MT350

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ellrider
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by ellrider » Sun Jan 24, 2010 12:15 am

Nice project :mrgreen:
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Bunker
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by Bunker » Sun Jan 24, 2010 1:25 am

marvelous mate!
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HD MT500e 'Bunk'
HD MT604e MTourer project


You don't need a parachute to skydive. You only need a parachute to skydive twice.

green_machine

Re: Transition from MT500 to Project Scruffy - MT604e.

Post by green_machine » Sun Jan 24, 2010 7:12 am

Pete,

I put the 500 exhaust system back on and also compared the route of the exhaust on my 350 before "arcing up". Fingers crossed that the new stainless system follows the exact same route.

Stuart
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Apophis

Re: Transition from MT500 to Project Scruffy - MT604e.

Post by Apophis » Sun Jan 24, 2010 7:47 am

looking good Stu
cant wait to see it powder coated :lol: :lol:

the center section of the exhaust should follow the same route
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bth2bth2
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by bth2bth2 » Sun Jan 24, 2010 8:02 am

the position of the filter looks almost perfect.if it looks right it usually is.well done.
thumbs up.
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Slowly slowly catchy monkey.............
CBR 900rrs , zrx1100.in green gone but not forgotten.....mt500 in green ,stolen and abused but still alive.......cos one day , all bikes will be this slowwwwwww

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Daj
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by Daj » Sun Jan 24, 2010 8:08 am

that's Inspirational Stuart! Well done mate!

Daj
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-----------------------------------------------------
Trying to find my own a*** with both hands
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MT500e
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Re: Transition from MT500 to Project Scruffy - MT604e.

Post by frenchy3 » Sun Jan 24, 2010 8:21 am

Fantastic job and well done. This would really benefit from going into the club files for future reference .
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MT 350 1996 The Albatross

green_machine

Re: Transition from MT500 to Project Scruffy - MT604e.

Post by green_machine » Sun Jan 24, 2010 8:53 am

I`ve had a dig through my photo`s and found this one showing Apophis`s stainless sytstem fitted. You can see daylight where the middle section of the exhaust routes round the frame giving clearance for my primary filter:

Image

Stuart
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