TÜV Approved: Yamaha SR500 Roadster / Scrambler

Workshop43 rescues a neglected classic…  

The Yamaha SR400 and SR500 were street-centric versions of the company’s 500cc TT/XT enduro bikes, which gained fame in the great African rallies of the late 70s. But their heritage went back even farther, to the postwar golden era of the British marques.

“The SR was a throwback to legendary motorcycles from BSA, Matchless, Velocette, Norton, and Triumph. It was arguably the last call for the golden-era British single formula, even though it was designed and built by a Japanese manufacturer.” –Revzilla

The SR was destined to become a cult classic, and one need not know a thing about the great British singles of yore to love the SR’s simplicity of design. In fact, the words of Cycle World from 1978 have proved prophetic:

“When all the above is said, done and forgotten, the SR500 will stand on its own. And will stand proudly. The concept of One Big Cylinder and no extras is good enough to not need any frills.” –Cycle World

However, with the earliest of these bikes now nearing 50 years old, too many of them have found their way into junkyards, garden sheds, and dusty garages from which they may never emerge.

Fortunately there are folks like Andreas of Germany’s Workshop43 who make it their mission to find and resurrect such forgotten machines. Andreas is something of a born petrolhead — as a boy, he built himself an engine-powered pedal car and never looked back, constructing everything from tuned 50cc scooters to a CBR-powered 100-hp go-kart!

Today, he has his own workshop in Mainz, Germany.

“Mainly we build project bikes and make custom parts. Not just the typical buy and bolt-on motorcycle builds. That is boring. The goal is to make each project better than the last.”

He found this SR500 in a garage, where it had been sitting for 25 years, and decided to bring it back to life.

“The design concept for this build was to transform a classic Yamaha SR500 into a modern scrambler that combines vintage aesthetics with contemporary performance and reliability. I was heavily influenced by the minimalist and functional design philosophy.”

Andreas did all of the work in himself in his shop, documenting everything on his Youtube channel. He swapped out the stock undercarriage for a set of 17-inch Husqvarna 701 Supermoto wheels matched with conventional Kawasaki ZX-6R forks, Brembo caliper, and a big front disc. The non-USD forks and 17-inch wheels with modern rubber increase performance without radically altering the look of the vintage bike — perfect for such a modern interpretation of the SR.

The engine was completely overhauled with a larger oil pump, additional oil passages, drilled fins, and other modifications. The big single now breathes through a hand-bent titanium exhaust system that Andreas built himself, inspired by his idol, Shiro Nakajima of Japan’s 46Works — a great point of pride in the build, and one that not only performs, sounds, and looks great, but weighs just a quarter of the OEM exhaust.

Other highlights include a rear disc brake conversion with Brembo caliper, Magura hydraulic clutch, YSS rear shocks, custom subframe and seat, custom tank graphics, and more.

But wait, there’s more. The whole build process was complicated by the fact that keeping a custom bike street-legal in Germany requires TÜV (Technischer Überwachungsverein / Technical Inspection Association) approval, which required a ton of work: “a significant achievement, involving extensive documentation and calculations.”

Andreas says all the work was well worth it, as riding the SR500 is nothing short of exhilarating.

“The combination of modern suspension and brake components…provides a smooth and controlled ride… The bike feels agile and responsive, making it a joy to navigate through city traffic or open roads.”

Kudos to Andreas for rescuing this neglected classic and turning it into a perfectly resto-modded roadster / scrambler that can handle urban traffic, backroad twisties, long tours, and even a bit of dirt. Below is our full interview with Andreas and the complete build sheet, and the photography credits go to Andreas’s brother, Stefan Wanning (@stefanwanning_photography).

Yamaha SR500 Custom: Builder Interview

What was the design concept and what influenced the build?

The design concept for this build was to transform a classic Yamaha SR500 into a modern scrambler that combines vintage aesthetics with contemporary performance and reliability. I was heavily influenced by the minimalist and functional design philosophy. I wanted to create a bike that not only looks striking but also performs exceptionally well on urban streets and maybe light off-road trails.

This project has been a labor of love, transforming a neglected classic into a modern scrambler with both style and performance.

What custom work was done?

I rebuilt everything myself in my private workshop. From the engine to the frame and exhaust system, I personally handled every aspect of the build. The handmade titanium exhaust system was inspired by my idol, 46Works from Japan.

The most important point is that this entire motorcycle is legally roadworthy in Germany, as all modifications were coordinated with the TÜV and are registered in the vehicle documents. This included extensive documentation and calculations to ensure compliance.

The entire build process is documented in a series on YouTube, and there are countless photos of the project on my Instagram (@workshop.43). The photos were taken by my brother, photographer Stefan Wanning (stefanwanning.com).

Can you tell us what it’s like to ride the finished bike?

Riding the finished SR500 Scrambler is an exhilarating experience. The combination of modern suspension and brake components, including the Kawasaki ZX6R forks and YSS shocks and Brembo calipers, provides a smooth and controlled ride.

The hand-bent titanium exhaust system delivers a unique and satisfying sound while riding. The bike feels agile and responsive, making it a joy to navigate through city traffic or open roads. The ergonomics are comfortable, thanks to the custom seat and Magura handlebars and clutch, allowing for long rides without fatigue.

Was there anything done during this build that you are particularly proud of?

I am particularly proud of the hand-bent titanium exhaust system with the Akrapovic titanium muffler. Crafting this exhaust by hand (with sand and flame) was a challenging yet rewarding process, and it was inspired by the craftsmanship of 46Works.

The exhaust not only enhances the bike’s performance (quarter the weight of the original exhaust) but also adds a distinctive visual element. Additionally, ensuring that all modifications were TÜV-approved and legally registered in Germany was a significant achievement, involving extensive documentation and calculations.

Is there anyone you’d like to thank?

I would like to thank my partners Kedo, Nassstrahlen-München, and YSS for their support and high-quality components that were crucial to this build. Their expertise and products helped bring my vision to life. I also want to express my gratitude to my brother, Stefan, for capturing final bike through his incredible photography.

Build Sheet

Base Motorcycle:
• Yamaha SR500
• Year: 1975
• Found in a garage where it had been sitting for 25 years

Modifications:
• 17″ wheels from a Husqvarna 701 Supermoto
• Forks from a Kawasaki ZX6R
• Complete engine overhaul and tuning (larger oil pump, additional oil passages, etc.)
• Engine and carburetor surface treatment through wet blasting
• Hand-bent titanium exhaust system with Akrapovic titanium muffler
• KTM EXC handlebar clamp
• Magura handlebars
• Conversion to rear disc brake
• Daytona mirrors
• Daytona Velona 60 mini speedometer
• Custom seat
• YSS shocks
• Magura Hymec hydraulic clutch
• Custom tank graphics
• Modifications and adjustments to the rear frame

 

Partners:
• Kedo
• YSS
• Nassstrahlen München

Build Videos

 

Follow the Builder

• Instagram: @workshop.43
• Youtube: www.youtube.com/c/Workshop43
• Photographer: Stefan Wanning (@stefanwanning_photography)