SR400/500 Hardtail Kit: Installation Steps and Points to Note

01 What is the hardtail kit?

With its redesigned hardtail kit, simply fitting it completely transforms the bike's silhouette. We skip the steps for disassembling the rear end and start from the point where the swingarm has been removed.

02 Extending the brake rod

The hardtail is longer than the stock swingarm, so other parts need to be extended to match.

1. Remove the pin from the brake rod and extend it by joining the included 6mm plate.
   
2. Once joined, refit it to the bike as before.

03 Left footpeg (shift pedal side)

1. Remove the footpeg, along with the bolt and rubber at its base. Into the now-empty mount, fit the included "short frame collar" from the outside.
   
2. Insert the "M12-65mm bolt" from the inside.
   
3. Onto the bolt sticking out on the outside, fit the "9mm plate" and then the footpeg, and loosely secure them with a nut.
   

04 Right footpeg

The right side assembles slightly differently from the left, so take care.

1. The right-side frame collar is shaped slightly differently from the left. This one goes in not from the outside, but from the inside of the frame.
   
2. Insert the "M12-70mm bolt" from the inside through the "9mm plate."
   
3. Fit the footpeg from the outside and loosely secure it with a nut.
   

05 Fitting the hardtail and rear wheel

With everything prepared, it's finally time to fit the hardtail itself.

1. Offer up the hardtail.
   
2. Secure the left side with the "M10-45mm bolt" and the "long spacer," and the right side with the "M10-40mm bolt" and the "short spacer."
   
3. Secure the top. The assembly is as shown in the photo.
   
4. Fit the "6mm plate" to the frame's shock mount with the original stock washer in place. Secure the hardtail and plate with the "M10-25mm bolt," then fit the "collar," the stock washer and the cap nut in that order.
   
5. The hardtail is now mounted on the bike. Re-tighten everything firmly.
   
6. Move the stock torque rod over to the hardtail. Refer to the photo for the torque rod's orientation.
   
7. Fit the rear wheel.
   
8. Secure the torque rod to the brake panel, adjust the chain and so on, and the rear wheel is mounted.
   

That completes the hardtail installation. Note that converting to a hardtail also requires separate mounts for the fender, turn signals, taillight and so on.

06 Points to note when fitting the hardtail

• The chain is 428-138L.
• If you use the wrong bolt length, you'll end up tightening it without the lock nut engaging, so be careful.
• The stock rear fender, taillight, turn signals and so on cannot be fitted. Modify universal parts or similar to suit the bike.
• With the stock side stand, the bike sits too upright, so modify or replace it to suit your bike.
• The footpegs lose their rubber mounts and become solid-mounted. The left footpeg is offset 9mm outward, so the stock rearset-type footpeg can't be used as is. Modify it to fit, or switch to forward-type footpegs.
• If the stock frame has weld spatter or scratches, or if the paint is too thick, the collars at the footpeg mounts may be hard to fit. In that case, adjust by filing them down or similar.
• With no shock-absorbing mechanism, vibration increases. Inspect the bike and re-tighten fasteners before every ride.
• If you've tuned the bike with a big-bore kit, racing carburetor or similar, we recommend upsizing the chain (520, 530) and adjusting the gear ratio with sprockets.