Harley Davidson XG 500 Dirt/Street Tracker Project (Full Video)

This was shot almost 3 years ago. Sorry for the slow posting i had it on a different platform and forgot to post it here.
Over 2 months of work, cut down to just under half an hour. This project was built for a Harley dealership and was a ton of fun and a ton of work. Keep in mind i have to do what they want on these bikes, and don't have 100% control over all the decisions. So if you think something should have been this way or that way keep it to yourself or better yet... build your own :)
Thank you so much for your support
-chris chappell
Check out my store here www.tuffside.com

[@milla6537]

That is what it should have been from the factory. Beautiful!

[@markgiles8527]

That’s right. Not a bad platform, just the styling was all wrong.

[@Peter-km7hb]

Harley-Davidson does not think out of the box until it's too late😮

[@robertz5958]

Gday Chris, I have to own up and say that I have never liked HD motorcycles! I almost skipped this video for that reason. However you have clearly created a piece of art! Thanks for taking the time to film and show the build! It shows what can be done with a bit of imagination and a sh__t load of skill. ( And the workshop full of drool over tools! ) Thanks again!

[@leonardodahumanoid4344]

Such a beautiful bike. I've been searching for the best street tracker designs on YT.

[@JackTheSkunk]

Beautifully executed. Street trackers are the only motorcycles I would love to own.

[@maxwellbricks7202]

With the declining sales of Harley cycles, just how hard is it for them to listen to those that want a lighter bike like this? Would buy this in a New York nano second.

[@Heavywall70]

When is Harley going to grasp that a street tracker would be light years cooler than those AWFUL Streets they’re trying to peddle?

[@miamimotogroup5371]

Or at least the option for a kit to build one.

[@torugotoh7550]

I don't like Harley , but I like this bike . Really beautiful ! ! Good work ! !

[@williamrae9954]

LSK lights from the Czech Republic....very high quality,ideal for these type projects....nice build!

[@johnnymcquinn6025]

You always do amazing work, one of if not my favorite builder. Have a new project I just started, plan on getting one of your seats and who knows! Like your videos, to the point and informative!

[@purebloodheretic4682]

*That's the Bike Harley Should have Made!! Awesome Job!!🇺🇸🇺🇸🇺🇸👍👍👍*

[@fzswede9533]

Looks great ! Cool that you’re back. Hope to see more stuff being made soon. The amount of work that goes into making custom yokes and wheelspacers and everything is rarely shown or talked about. 👌🏻

[@gangxerboy]

Finally !! three years of waiting after the trailer

[@paulbecket7399]

if harley did this they would have no problem increasing their sales

[@peteransel2715]

Hats off! The balanced proportions of this very creatively designed build are incredibly close to perfection. Let's get these into production and into the hands of some motivated dealers. These would sell well in New York City, and in European cities as well, where 500 -750cc bikes like the Guzzi V7 and MT-07 have done very well. Count me in as an investor! Have you sent photos into BikeExif or PipeBurn yet? Once you do, your phone will be ringing off the hook with orders! Cheers and well done!

[@tuffsideseats]

Thanks! Yes just search Pipeburn for "chappell customs" it was featured back when i built it in 2016 :)

[@MrJoseefus]

Absolutely beautiful build!! So glad I found this channel!!

[@peacefulwarrior4078]

Hey Harley Davidson these are the style of harleys that will have no problems at all !!!

[@stevendavies8496]

The exhaust is how it should have come from the factory, and would shut all the moners up ,,,really nice work

[@jasonmiller9495]

Harley should make something like this for production

[@JR-bj3uf]

Just the position of the foot pegs in relation to the exhaust over the stock XG is worth the effort. It looks like the bike is actually ridable.

[@Oddman1980]

My first Harley was a Street 500. Put 8,000 miles on it and the only time I had to put a wrench to it was to change the oil. Love what you did with the XG500 in this video. I have a 750 Street Rod now, and I'd love to either build a new exhaust myself or have one made. How much of a difference did the FP3 make?

[@hallatrineer2714]

That's really some fantastic stuff. I'd love to see more harley engines offroad.

[@zardportugal]

What a cool upgrade, Chris. Cheers.

[@johnbrady1211]

Oh, Lord if I only had a machine shop like that. I'd be building some serious bikes.

[@discmotoslots]

very nice work! prob need some kind of chain guide/roller similar to a dirt bike set up

[@dlux703]

Beautiful build. My only concern is the radiator cover doesn't look like it will flow enough air into the rad. to keep the temp. down.

[@bowlingmatt1]

What a great build. Sad the dealership took it before you were absolutely done with it.

[@adancampos2011]

I have an XG 500, how much did everything cost to make it this awesome???

[@stephenschneider9209]

Complete badassery right there.

[@bart7427]

It’s been a long time, bud.

[@robertrishel3685]

Harley should already be making this very bike. Excellent work., bike looks bitchin’

[@amorph28]

I would really like to find a chain conversion kit for the XG750 stock wheel. Why haven't any of the great tuners of this motorcycle released this update yet? Or a complete set with spoked rims for factory brakes...

[@robertrishel3685]

Really cool. What did the bike weigh before and after? Could you have used more aluminum instead of steel and saved a few pounds?

[@devangrey5676]

How much does a project like this run? Starting from a fresh new bike?

[@kevinbergeron4702]

likely ROUND 20 TO 30 K

[@jamppa4693]

@@kevinbergeron4702 20 to 30k???! Bruh its a motorcycle. 5-7k is realistic

[@chrisdawson8252]

@@jamppa4693 they probably used gold plated rims ibstead of powder coating. And lot of titanium and carbon fiber parts 😂

[@danmcelroy6584]

Nice build! 👍👍 However if it ever went into production the exhaust would need changed and moved to a position that most on and off road bikes have.

[@wwekidder123]

Beautiful bike nice job although you could have cut that headlight / Fork cover into the shape of the Harley-Davidson logo I think would have been a better look as opposed to square but hey what do I know👍

[@lucas_bryz]

Does your company sell that tail section and seat that you designed for this XG500? I have an XG750 and would love to do this to it.

[@stevenhumphries110]

Absolutely spot on....not being rude but whats it worth with the build etc ??

[@bonesport529]

I envy your skills, I surely do. Great job

[@petephillipps1485]

Great looking bike, What is the rim size and where did you get them. I'm currently building an 883 flat tracker

[@tuffsideseats]

Hit up my guys at blackbikewheels and tell them Chappell Customs sent you.

[@petephillipps1485]

@@tuffsideseats Cheers Chris.

[@charlesduggan7600]

Fantastic work fella!

[@robertwells6454]

Looks cool, tank look a bit off to Me. A bit big when Your close to it. Looks better when You get away from the bike though. 🤟

[@lesblack8036]

Jay spingsteen number 9 cool.

[@oneofmany1087]

The Master of Flattrack

[@davespears2241]

Really impressive.

[@billybike57]

Awesome work!👍🏼

[@timclapin3488]

nice concept, i realize it had to be done fast but a little rough for my liking, the sharp point on gauge mount, re-using the lump of steel to mount master cylinder, the numbers look terrible,

[@brandonpartin37]

is it bad that i instinctively looked away when he was welding?

[@BEETLEJ00CE]

Beautiful bike !

[@miker9585]

Amazing work!

[@lcrgarage3245]

Great looking build.

[@brettstriegel6249]

What size wheel/tire combo are you running?

[@alneno9840]

i like everything except the YAMAHA R1 front end..maybe a vintage style modern front end would look better other than that your builds are AWSOME..

[@phlodel]

Look better but perform like crap.

[@ngokevin6708]

Awesome bro !!! Love it

[@alstone5257]

WOW looks great !!

[@fonsecahebo]

How much more did you slot the swingarm.

[@bradbradbury2693]

Love the seat unit , was that a custom unit or did you purchase it ?

[@tuffsideseats]

i made it, but i was in such a rush i didn't make a mold to make any more . Check my website (TUFFSIDE) for other options. Thanks

[@bradbradbury2693]

@@tuffsideseats hi Chris thx for that will certainly check it out. Beautiful build congrats

[@ericweber1969]

Chris Chappell looks like it's one you should consider selling. I'd look at buying one of these bikes, just to do this conversion.

[@michaellee9295]

I would totally buy a street 500 if it came from the factory like this.

[@MrJeepmarine]

Great work, sharp bike.

[@brianmarkel2072]

How much for a street legal build like that?

[@frankmlchaelglasscock6539]

That is one cool bike 👌💯💯💯👍👍

[@turbogrin]

Great REBUILD !! But how does it Sound ?

[@tuffsideseats]

watch the vid.... bikes running at 25:00

[@turbogrin]

@@tuffsideseats Wooops My bad I skipped over it at about 22 min then to the end !!!

[@gregoryunderwood4121]

Amazing job!!!

[@cwest7333]

Lookn awsm! What size are the wheels and tires?? Thx

[@Hamsa3600]

goood job guys .... relly lovely litle FT .... how many HP a 500 HD has ?

[@thomaslemay8817]

I looked it up found a claim of 68hp and 47ftlb torque.

[@Vsmechanical_llc]

Do yo have the tank lifter for sale?

[@elariete8552]

¡Increíble hermano!

[@udayshome1793]

What LED striplight is that for the backend?

[@lochieevans7847]

What exhaust you guys running

[@samb2108]

Could have should have got the shocks in black. But overall...knocked it out of the park!!!

[@danogle9927]

NICE , Very nice !

[@tonyspivey5336]

Nice work.

[@sunconsecutivewin8687]

WOW!! very nice!!👍👍👍👍👍👏👏

[@bougie2k]

like you said ...you dont like it ...build your own ........good job

[@laxmanbikramthapa]

tips to raise the tank!!

[@JohnSobaski]

Getting ready to build me one more Street Tracker 650 access Yamaha and you know why it's go pissed and make it 7:50 and cut that Cam and make it a twinkle~°•°~

[@theo180195]

Very good job

[@mihailokacarevic6945]

What are those tires? I'm guessing they're tubes, or did You seal the rim?

[@tokyosmash]

Sealed wires exist

[@mihailokacarevic6945]

@@tokyosmash I'm aware, thought they are BMW specific, thanks.

[@tokyosmash]

Mihailo Kacarevic I’ve seen a few of the companies that build high dollar wires do sealed jobs, there are kits to seal conventional wires though. Have been eyeing one for my Royal Enfield.

[@mihailokacarevic6945]

@@tokyosmash Yeah, just googled it. Seems extremely expensive for a cx500, and i dont really trust those kits. Going tubed probably. Thanks mate.

[@tokyosmash]

Mihailo Kacarevic it really does, it’s like what, $200? I don’t have any issue with tubes honestly.

[@forestjump3r516]

Need to sell this as a kit

[@lancestone4409]

What is the song at the end?

[@tuffsideseats]

My nephew makes all my music for my videos. his youtube username is twitchyAMC (inzen)

[@thefirstdutchguy]

top notch!

[@dublion7]

Awesome 👏

[@didierboutry9582]

Magnifique

[@tokyosmash]

Song starting at 6:05ish?

[@metalgamedog]

great🔥👊🏻🔥

[@sonnypena194]

I'd buy that bike.

[@oscaremiilio]

Technically the exhaust does not apply for an street tracker.

[@bobbygarrison3122]

Very nice, $$ figure for this bike.

[@thomaslemay8817]

You said dirt/ street tracker no turn signals and horn not street legal. This bike is close circuit only !

[@AmericanPiddler]

I want this triple tree 🤤🤤🤤

[@摩伽羅魚太郎]

super cool rear set foot rest 日本で売って欲しい

[@needmetal3221]

These bikes are being discontinued

[@peacefulwarrior4078]

Must've been a rider safety course bike ! Lol at my local Harley dealership I've seen 3 that had the entire front ends smashed backwards to the frame from inexperienced riders fuck ups lol

[@REDCLAYHOMESTEAD]

I was thinking that's a lot of money and effort for something that isn't streetable, and also doesn't meet standards for most flat track racing till I remembered it was going to a dealership and they could just throw a dealer tag on it and have some fun if they want between shows.

I WANT IT I WANT IT I WANT IT

[@sureshvadakoot1133]

A bit disappointed that you don't show the build completely. Sorry but didn't quite enjoy the video. At least a time lapse would have been good. But the end result is amazing!

[@tuffsideseats]

bike took months to build. Impossible to document the entire process unless you send a camera crew. I have a job to do and deadlines....

[@mhilde7744]

I would f%ck that bike if I could. Awesome!

[@PepperGeorge]

Headlight section is kinda ugly

[@manakara5]

white noise music

[@alexc2505]

What a waste if it's a show bike and doesn't get ridden .

[@sinsinsss5216]

Its dificult but u can more better dude. Also i dont know i an imitating u or not. I dont know to many think i confuse hahahahaha