XV535 hub modification

This shot shows the area that needs to be removed to fit the 750/920 splined drive adapter. I went over the surface with a sharpie to show high spots when trying to fit the splines. Keep grinding that edge down until the drive adapter sits flat on the hub.

It would be neater on a lathe but in my case it wouldn't fit. Grinding with a dremel tool also means not having to remove the rim, convenient if you intend to keep the stock 15" from the 535.

Spoke wheel conversion - bearing selection

My local motorcycle store managed to lose the top hat spacer I had fitted in the XV hub when they installed the tire.

The main reason for having to make a top hat spacer for the drive side bearing on the XV535 hub is that the required bearing is an odd size. The commonly available bearing to fit the hub ID 42mm is the 6004 which has an ID of 20mm.
There is a bearing that would fit and match the larger XV 750/920 axle OD but it's harder to find. The 6303/42 hybrid bearing is 42 OD, 17 ID, the only problem being finding a sealed version which is why I made the spacer. However, it looks like Honda part #91003-KRM-841 from a CRF 150 transmission is sealed, I just ordered one so fingers crossed!

Wow, almost 3 years later...

Enthusiasm for this project is back, should be making headway shortly!

XV spoked rear wheel conversion info part 1

Here's a diagram of the XV 535 spoked hub as set up to work on the XV 750/920 final drive.
More info to follow...

XV Cafe Racer Video

Here's a rather nice XV cafe racer from YouTube, looks very neat and sounds lovely. The dual high-level exhausts are very interesting...

Photoshopped tank and seat

Photoshopped image showing the chassis with tank and seat unit. I didn't opt for a tank and seat until I had checked the proportions relative to the rest of the bike in photoshop.

It's a roller!

Very productive couple of days saw the fitting of a Virago 535 spoked rear wheel. I will post photos/details shortly. The rim is 15" and will eventually be swapped for an 18" but for now it will work while I focus on other parts of the build.

Here's a quick side shot to allow me to try different virtual tank and seat designs