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Big Berg April 5th, 2015 01:49 PM

1992 fc501 Resto/mod build

After finding virtually no info or pictures (even from Malcolm Smith Motorsports) of what I was told is a Malcolm Smith Edition 501 and deciding against building a Joel Smets replica out of it, I decided to just build the bike the way I would like it.

The engines top end is completely rebuilt with new piston set, valves, timing chain, tensioner, and stator. I also installed a modern FCR41carb. Shock and forks rebuilt as well.

I rode the bike a couple times and thought it was cool. Totally different then my other big bore bikes. After having many years experience on big bore 2Ts (CR500s, CR480, YZ490, KTM380) and my fe650 I would say the bike is like a XR650 power wise with a much lighter and better suspended chassis.

I want to keep it looking similar to the original 92 fc501 look (Blue and Yellow), but with some updates, custom pieces, and my own modern styling cues.

This build will be an on going process. As time permits (back in college full time).

To start I fully disassembled and cleaned frame. I think I may have it media blasted and I will paint myself in original blue. The wheels were fully disassembled and the hubs castings smoothed and will get the same color blue as frame. I love black wheels, so I had the original rims powder coated. Spent a ton of time cleaning the SS spokes and nipples as well. I have decided to remove the ugly casting marks on the fork clamps and paint them black which will match (so far) the 1-1/8" handle bars, restored radiator, and new sprocket. I also restored the original muffler and header pipes. I want this bike to be as quiet as possible, but still sound good. I have also purchased a bunch of new parts so far for the bike. Next purchase will be new tires for the wheels sets that hopefully will be painted and assembled by next weekend-ish.

I have some pics to post now. All comments welcome.

This is the bike before resto/mod-

tourist April 6th, 2015 06:22 AM

more! more!

Big Berg April 6th, 2015 06:14 PM

Here a pic of the FCR-MX41 carb with modded inlet.

steve April 7th, 2015 04:14 PM

Looking forward to more of this. I've got a set of the older plastics that I thought I'd add to my 98 FE501 one day when I do it up, I do like the original style of these.

Big Berg April 7th, 2015 07:07 PM

Steve, you have a new (older) set of 91-93 plastics?

Restored the WP forks-

steve April 7th, 2015 08:03 PM


Originally Posted by Big Berg (Post 160469)
Steve, you have a new (older) set of 91-93 plastics?


Sort of, 2nd hand, but new to me. Found them on eBay a few years ago and been sitting on the shelf waiting for the day to arrive. Need some polishing and scratch removal but all sound otherwise.

Big Berg April 10th, 2015 06:04 AM

Making this bulky front engine bracket more aesthetically pleasing the caveman way.

Looking for some INEXPENSIVE soft/mid tires to put on the resto/mod wheel sets that I am building. I am looking at the Artrax SE3 combo. I like big back tires :-)

Anyone have any suggestions?


Big Berg April 12th, 2015 07:36 AM

Smoothed, prepped and ready for primer-

Primered and waiting for Husaberg Blue-

Oregon Trail April 12th, 2015 08:20 AM

So for those who don't know anything about those Artrax tires. They are imported into the US by The price is super cheap at $99 for the set, they work good for about 6 months, while the knobs are still ok, the side wall has broken down and gives you that flat tire feeling. I usually run 13 lbs, but have tried 15lbs, 16lbs and will now try 17lbs. At 16lbs you can wiggle the rear tire on the rim.

Big Berg April 12th, 2015 08:46 AM

Mike, Have you found any other good deals on tires?

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