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HL replica frame kit
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HL replica frame kit
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HL replica frame kit$3,300.00

Replica frame kit for the Yamaha HL 500

This frame is a direct replica of the 78 model UK built NVT frame (Norton-Villiers-Triumph)
Frame tubes and major frame gussets are all made from 4130 Cro-Mo and all frames are heat treated after manufacture to normalize the Cro-Mo.
Swingarm is made from 6061 Aluminium & heat treated to T6 after manufacture.

A few improvements were made along the way. The original frames had some problems with cracking around the swingarm pivot in the square box backbone that sits behind the engine. This section has been increased in thickness to 2mm, up from 1.5mm. This section is also made from 4130 Cro-Mo as are all the frame tubes and major frame gussets.

The original frames had very minimal chain clearance so the frame tube from the swingarm pivot to shock mount was also moved outwards 5mm and the shock mounts on the frame & swingarm are also moved outwards by 5mm. With today's O ring & X ring chains being common place the extra clearance makes the frame more user friendly without losing the original frame design.

The basic frame kit comes with...
# Frame
# Swingarm
# Rear brake pedal
# Alloy engine mount plates (upper & lower)
# Oil cap
# Drain bolts
# Long lower engine mount bolt

Swingarm is polished and frame is left in raw metal.
Rear chain guide plate underneath rear of swingarm is left undrilled to allow for the fitting of any chain guide.
Oil lines will have to be custom built, most hydraulics supply workshops should be able to help you with this one.
I am working on an oil line kit for future purchase.


Overseas customers please note that our local tax (GST) of 10 percent will be removed from the final total at checkout.


The HL500 is built from some standard Yamaha parts and some special build parts.
I have endeavored to recreate all the unobtanium parts so that anyone wanting to build a replica can build to their own unique specifications.

# Motor
Any XT500, TT500 or SR500 (76 to 81) motor will bolt straight in. Despite the fact that the SR is a street model or the XT is a road / trail model all motors are virtually identical. All 3 models share the same pistons, cams & gearing.
All models share the same exhaust valve however the inlet valve is larger on the 80 & 81 model TT's & XT's and all the SR's.
The 80 & 81 model XT's used and electronic ignition but it is different to the SR electronic ignition, it is not advisable to mix and match CDI's from different models.

Fuel tank and seat
These can be sourced from the...
# YZ 100 C - 1975
# YZ 125 C - 1975
# YZ 175 C - 1975
# YZ 125 X - 1976

I now have replica seat bases available.

Wheels and forks.
These can be sourced from YZ 250's and 400 / 465's from 77 D models up to 81 H models.
Later model parts may still fit as Yamaha kept the same headstock dimensions for many years and although the rear axle diameter increased some hubs can be brought back to earlier specs by fitting the earlier bearings.
Chain adjuster hardware can be sourced from the following models...
Part # = 2K8-25388-00-00 Part Description = PULLER,CHAIN 1
TT500G 1980
TT500H 1981
YZ250E 1978
YZ250F 1979
YZ250G 1980
YZ400E 1978
YZ400F 1979
YZ465G 1980
Part # = 90381-17027-00 Part Description = BUSHING,SOLID
TT500F 1979
TT500G 1980
TT500H 1981
YZ250E 1978
YZ250F 1979
YZ250G 1980
YZ400E 1978
YZ400F 1979
YZ465G 1980

Footpegs
I have fabricated footpeg brackets available which have the mounting tags further apart than the originals which allows for the fitting of later model pegs.
The original stock mounting brackets can be found on the following models
Part # = 1W4-27412-10-00 Part Description = BRACKET,FOOTREST (LH)
YZ250D 1977
YZ250E 1978
YZ400D 1977
YZ400E 1978
Part # = 1W4-27422-10-00 Part Description = BRACKET,FOOTREST (RH)
YZ250D 1977
YZ400D 1977
YZ400E 1978


Out of stock