SuperMoto wheels

Getting frustrated researching this topic only to find many answers that require too much bubblegum and Band-Aid engineering. Has anyone, ever, found a set of wheels off any motorcycle, ever made, that will fit a 2009 510 and hold street tires? Cast with a cush drive would be great.

Please be aware I'm not looking to drop a grand on new (or used) wheels. That's just insane IMHO. Many stock takeoffs can be found for less than $100, just need one that fits, such as: the correct axle size, how wide of a wheel will fit without shaving the tires, correct offset, etc. I have a lathe, so making spacers to offset the wheel isn't a big issue except it pushes the tire further right into the swingarm, requiring a narrower wheel. I can't be the first guy to ever think of it and don't feel that "wrapping shim stock around an axle to tighten it up as it goes through the fork" is safe. Somebody, somewhere has surely found something that works. Please chime in!

Sorry if this sounds rude, but I've been at it for weeks and found lots of combinations that people have done, but nothing that'll bolt up right.

All I can offer is; Huskys are fairly rare when it comes time to retro-fitting from common JDM parts. Look around ebay for 17" wheels from SMR Huskys or try Supermotojunkie. They won't be as cheap as you hope, but they will bolt right in.
I've spent WAY more than I hoped when I wanted to upgrade from the stock wheels.
I spent the extra $$ to get a cush drive only to find out our euro wheels have a different spoke angle than stuff made for the typical Honda/ Yamaha, etc.

I think you will find that it will take ~ $300 just to get a pair of decent 17" tires even after you have the wheels. Then don't forget two rotors and rear sprocket.

I wouldn't get too hung up on the axle size, you can change the bearings to suit your axle. I had thought of this too, I would think something like a 250 or 400 road bike wheel would be around the right size. The distance between the disk and sprocket is critical and overall width of the wheel the rest you can make to fit.
But in the end proper supermoto wheels are the way to go, warp 9 are what $895 with the disks, sprocket and brake relocator. Plus you can sell them when done for not too much of a loss

Since you have the same bike as me, the bolt on sollution is the wheels of the smr 610 (2008-09)
I have a set of it in the garage that I don't use very often ...

Any Husqvarna 4st wheel from 2004 and later will bolt onto your bike. I put a set of 610 wheels on. I think you will have to adjust your expectations WRT price. $600 seems to me the going rate for a set of SM wheels.

For instance, found a pair of GS500e wheels with tires, brakes, axles, and sprocket for $180. Too bad they are 20mm axles and the rear is only 3.5 inches wide. Old ZX-7s are supposed to have 25mm axles, but are 5" wide, probably too much.

Can't find any 610 or 510 SM takeoffs anywhere.

Just scored a set of stock SM wheels, complete with rotors, sprocket, tires, and front caliper bracket, that a guy had mounted on his '06 te510 for $550. Best part is its about 2 hours away so I'm picking them up! Now that's more reasonable!