Modern supercars are complex machinery, both inside and out. Not only have their engines and electronics evolved dramatically over the past few decades, but their bodywork has also completely changed. Aerodynamic packs developed for MotoGP racing are now being applied to street bikes, so it’s normal for OEM superbikes to have wings sticking out of the fender.
Like many of us, Josh Merrill misses the days of speed bikes with thin bibs… so he built one of his own. Based on 2022 specs YAMAHA XSR900and wrapped in a ’90s race track body, his latest custom build is a modern classic of the highest order.
Technically, the Yamaha XSR900 isn’t classified as a superbike—but it’s not far off either. Its 117.4 hp / 93 Nm is nothing to scoff at and its chassis feels sharp and focused. And if you’ve driven it, you know how awesome its three-cylinder engine is.
Josh currently works for a major OEM, but he is also the team leader of a MotoAmerica racing team and runs his own industrial design business. With a decade in the motorcycle industry, he knows what works and what doesn’t.
“I have experience in motorcycle electronics, engine operation, chassis, exhaust and component fabrication, as well as years of racing experience for both myself and professional racing teams,” he said. with us.
“I also worked at various racing shops, one of which focused on vintage racing bikes. This taught me that although I like the classic look, I don’t like old bikes with old parts, heavy frames, and outdated parts.”
Using the Yamaha XSR900 as a sponsor was easy for Josh, especially since the 2022 model features a number of upgrades over its predecessor. The trick was to combine parts with a bike that matched his classic theme without compromising on performance. Working at Create Moto—a shared motorbike garage in Milwaukee—he started a business.
To complete the look, Josh turns to the history of Yamaha. Inspired by the legendary 1992 Yamaha YZF750, he ordered a YZF-made racing bib and belly cover from Airtech Streamlining. All he had to do then was figure out how to fit it into the XSR.
For the bibs, Josh built a series of racks from steel sheets and tubes, with the upper bib mount also housing the instrument cluster. A trimmed racing windshield from Gustafsson Plastics wraps up the front end. At the bottom, the Airtech belly has been modified to match the XSR’s frame.
In Josh’s favor were the original XSR900 fuel tank cap, side covers and saddle; a testament to the bike’s neoclassical vibe. So, with the bib and belly panel ready, he just added a passenger seat cover from Funny Customs in Japan. Remarkably, everything fits together as if coming from the same source.
Without really needing to subdivide the engine boxes, Josh focuses on the relatively easy power-ups. These include Akrapovič’s all-titanium exhaust system, DNA air filter and ECU flash, powered by 2 Wheel DynoWorks.
Next, the front brake system is treated with an upgrade from Core Moto, integrating brake pressure ports, because he plans to install a data monitoring system in the future. Josh added 310 mm rotors from Braketech, with longer pins and spacers to reposition the calipers. They are equipped with race track pads.
Josh plans to upgrade the XSR’s fork, rear shock, and rear brake at some point. Why not now? It’s simple: he’s waiting until there are more options on the market.
However, that doesn’t stop him from throwing a bunch of other top components into this build. Yamaha benefits from a GB Racing engine cover, an Evotech performance heatsink, and a Motion Pro coolant recovery tank. Josh also installed an adjustable rear set, 1-inch lift clamps, and Woodcraft rear kickstands.
Moving on to the smaller stuff, Josh has 3D printed a bunch of custom parts, including plugs to fill OEM riser mounting holes and brake line mounts as well as mounting plates for the sides of the apron. The R6’s clutch cable and is attached to a custom end bracket designed to help it remove barricades. The full addition of Pro-Bolt screws completes the spec.
You’ll notice that the XSR still has the taillights and license plate holder, but no front lights. Josh is on the fence; he can leave it like this, or he can add a crank with headlights.
Completing the construction is a Kenny Roberts-inspired paint job. What’s really clever, though, is that Josh designed all the graphics to complement the bike’s original fuel tank cap design, which was still intact when it left the factory. New parts are color-matched by FineLine Design to match the OEM look and decals created by Inline4Designs.
Now dubbed ‘XSR900R’, Josh’s bike is the perfect blueprint for a modern sports bike with a classic look. Hope Yamaha is paying attention.
ByJMR Design | Facebook | Instagram | Image of Brooke Tilidetzke
