DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: two-smoker on Dec 25, 2010, 22:59:40

Title: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 25, 2010, 22:59:40
So I found a deal I couldn't pass up- THREE XS500's for $500! Only one is titled and running (sorta), but it's better than none, yeah? I'll post pics as soon as I take some..... I have to actually pick the bikes up first... AND find someplace to keep them/work on the one. I probably shouldn't have bought them, but too late now! As an aside- If anyone needs parts, I'll let the parts bikes go for NOTHING if you come get them. Well... Once I get mine road-worthy. Wish me luck!
Title: Re: My new project!
Post by: Rocan on Dec 26, 2010, 00:15:02
saweeeetttt!

where ya located?

pics?
Title: Re: My new project!
Post by: two-smoker on Dec 26, 2010, 01:37:47
I'm in Milwaukee. Prolly won't get to taking any pics til Monday when I pick up the bikes..... Gotta get a U-haul, and a place to store/repair them...
Title: Re: My new project!
Post by: teazer on Dec 26, 2010, 01:48:44
Do you have at least one title so you can put one back on the road?
Title: Re: My new project!
Post by: two-smoker on Dec 26, 2010, 01:58:44
Ohh yeah, I wouldn't have bothered otherwise. One bike is titled and runs off starting fluid. Carbs are junk. One which is missing a tank (used to be purple. Cool color) has only 6600 miles on it.(correction- 9860. This is the motor I used the head off of to repair my runner. TS) So I'll see if there's anything wrong with that engine and try to use it rather than the engine that's in the titled bike. That one looks like it might have the obligatory cracked head. 
Title: Re: My new project!
Post by: two-smoker on Dec 27, 2010, 18:07:02
Pics! (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/SANY0008.jpg)(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/SANY0009.jpg)(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/SANY0010.jpg)
Title: Re: My new project!
Post by: VonYinzer on Dec 27, 2010, 18:26:14
Good get man!
Those 500s are a pretty under rated scoot. Theyre not the simplist things out there, but you can build some really awesome bikes from them.
The frames are perfect for cafe styling, and the early square tanks look the business.
Plenty of power, and they handle pretty nicely with some suspension upgrades as well. I have seen some info floating around on engine modifications for them that can produce some pretty amazing numbers for a 500.
All in all, you really scored T.S.
No get to work!!!!  >:(
Title: Re: My new project!
Post by: teazer on Dec 27, 2010, 18:36:25
looks like a steal.  Did the PO tell you why he had 3 of them?  Maybe he had an issue with bike #1 and bought a couple of others for spares. 

With 3, you should be able to get one good bike out of it and maybe a second. Good catch
Title: Re: My new project!
Post by: two-smoker on Dec 27, 2010, 22:42:59
He never really tried to do any serious work.... The Black one and the Red one were a package deal, and he picked up the purple one (with no tank) later. He's kinda of a "junk man". Had a shit-ton of bikes and parts. An old Bridgestone, a 400 Silverwing directly imported from Japan (with title), an XS850 Midnight Special, a DOHC 750 Honda, and an old 550 Honda which was all hacked up. Sporty tank, tractor seat, welded-on solid struts.... He really wanted me to buy something else from him. I guess that's just what he does. I guess he's got another property full of bikes, too.
Oh, and the "runner" is REALLY ratty. I think I'm just going to strip the frame clean and start over with the good parts off the other two bikes. The purple one has really low miles on it, and was stored in a heated basement.


Just an idea I'm play(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/xs500highpipes.jpg)ing with for exhaust- found this bike on Ebay:
Title: Re: My new project!
Post by: Reinhard on Dec 27, 2010, 23:23:28
Nice find dude
Title: Re: My new project!
Post by: two-smoker on Dec 27, 2010, 23:46:30
Also part of "the Plan" :(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/mv1753.jpg)
edit: I had wanted to do a bike with a dustbin fairing for some time. This bike just isn't it. Maybe if I do my FZ600/Seca turbo hybrid with the turbo above the motor, that will be the right bike for it. I keep imagining having the exhaust exit right out the side of the fairing like an old fighter plane...
Title: Re: My new project!
Post by: two-smoker on Dec 30, 2010, 02:25:20
Took a minute today to look some things over, and found out the titled bike is actually a '73 TX500, the black parts bike is a '74, and the purple one is also a '73 TX500. Damn shame none have the automatic camchain tensioner..... I'm not real pleased with that fact. And I HATE breaker points, but can't find an electronic conversion for these bikes anywhere. i assume nobody makes one.
Also- I can't find a Manual either! I'd really like to have a book for reference before I do anything in earnest. edit: got one now! Lol. The last thing i want to do is start tearing into the motor and find out i can't put it back together....
If anyone can help, I'd really appreciate it.
Title: Re: My new project!
Post by: VonYinzer on Dec 30, 2010, 15:15:36
http://cgi.ebay.com/YAMAHA-500-TWIN-TX-XS-500-73-HAYNES-MANUAL-BOOK-/250739657938?pt=UK_CarParts_Vehicles_Manuals_Litterature_ET&hash=item3a613f8cd2 (http://cgi.ebay.com/YAMAHA-500-TWIN-TX-XS-500-73-HAYNES-MANUAL-BOOK-/250739657938?pt=UK_CarParts_Vehicles_Manuals_Litterature_ET&hash=item3a613f8cd2)
 
http://cgi.ebay.com/ebaymotors/CHILTONS-YAMAHA-XS1-TX650-TX750-TX500-Service-Manual-_W0QQcmdZViewItemQQhashZitem255f24023cQQitemZ160509985340QQptZMotorsQ5fManualsQ5fLiterature (http://cgi.ebay.com/ebaymotors/CHILTONS-YAMAHA-XS1-TX650-TX750-TX500-Service-Manual-_W0QQcmdZViewItemQQhashZitem255f24023cQQitemZ160509985340QQptZMotorsQ5fManualsQ5fLiterature)
 
 
Best I can find in a quick search. Call your local Yammy dealer and ask if they can get you a factory repair manual. It wont be cheap, but Im sure they can. The Chilton book is pretty spot on though.
 
As far as elec ign. there was a recent post somewhere on the site about a company that makes them. They are discontinued, but will be available in the next couple months I believe. Try doing a search, im too lazy, sorry. ha ha
Title: Re: My new project!
Post by: two-smoker on Dec 30, 2010, 17:39:05
Thanks, VonYinzer, I did find newtronic and yes, they did discontinue the TX500/XS500 unit.
Title: Re: My new project!
Post by: white orbs on Dec 30, 2010, 18:56:46
nice find,I might have a pdf manual gotta search . Could you help a brother out with two front caliper bolts?
Title: Re: My new project!
Post by: diesel450 on Dec 30, 2010, 19:23:29
Check the post about manuals by kodiak in the manuals section he provides a link to just about every manual out there.

Also, check mikesxs.com about the ignition. if they don't have anything online give them a call.
Title: Re: My new project!
Post by: two-smoker on Dec 30, 2010, 19:40:28
White orbs, shouldn't be a problem, assuming I have more than one set. Diesel 450, thanks, I didn't know Jake had those, I'll hit him up.
Title: Re: My new project!
Post by: MotorbikeBruno on Dec 30, 2010, 19:48:46
I picked up one of these a few months back. Got her running, and first thing I would tell you to do is ADJUST THE VALVES!!!! I was even told by the "older" mechanics that you should adjust them a tad higher than the books say.  I've got a set of handlebars in perfect condition if you want em.  Here's what the old gal looked like when I sold her with a busted head gasket...  :'(

Title: Re: My new project!
Post by: two-smoker on Dec 30, 2010, 23:33:15
Yeah, I've read up enough to know that these things are known for certain..... character flaws. I already know my runner has a cracked head, but with a low-mileage spare motor, no worries. Once I find a manual to explain how to do it, first order of business is a valve adjustment and oil change. Then, clip-ons!
Title: Re: My new project!
Post by: MotorbikeBruno on Dec 31, 2010, 10:41:28
Very cool.  I went with the drag bars, I am very curious to see what it would look like with a set of Clip-ons. I bet its going to look awesome.
Title: Re: My new project!
Post by: tv321406 on Dec 31, 2010, 12:19:01
two smoker; I also just purchased a TX500 recently. I was able to obtain a brief manual from ebay which is only about 5 pages long or so, but has very clear exploded diagrams of all of the major assemblies. Very useful in rebuilding the motor. It has JUST enough info in it. I'll see if I can't scan the pages for you on Monday. Also, I am working on making an entire gasket set with the CNC router at my work. The gaskets seem to be hard to find and expensive, so I just scan the originals into the computer and then send them out to the router, which cuts them out perfectly. Send me a PM and let me know if you are interested in the manual I have and if you might want a gasket set when I finish them.
Title: Re: My new project!
Post by: tv321406 on Dec 31, 2010, 12:19:36
oh, and does anybody have any sources for a head gasket?! I can't make those, since they have the copper insert.
Title: Re: My new project!
Post by: two-smoker on Dec 31, 2010, 12:21:12
Yeah.... I'll probably be spending quite a bit at Dime City Cycles.... Clipons, Mikunis, bar-end signals and mirrors, Acewell guages..... Man I'm gonna be soooo broke!
Title: Re: My new project!
Post by: two-smoker on Dec 31, 2010, 12:28:49
TV, I've found a manual, but i AM interested in some engine gaskets. Cam cover and side covers specifically. Lemme know if that's possible, eh? Thanks.
Title: Re: My new project!
Post by: Slice on Dec 31, 2010, 12:36:41
3 for 500 bones is a SOLID deal... Nice find man!
-Slice

So I found a deal I couldn't pass up- THREE XS500's for $500! Only one is titled and running (sorta), but it's better than none, yeah? I'll post pics as soon as I take some..... I have to actually pick the bikes up first... AND find someplace to keep them/work on the one. I probably shouldn't have bought them, but too late now! As an aside- If anyone needs parts, I'll let the parts bikes go for NOTHING if you come get them. Well... Once I get mine road-worthy. Wish me luck!
Title: Re: My new project!
Post by: kodiak on Dec 31, 2010, 14:08:55
Can't wait to see what you do with these, bud! You're last build looked pretty sweet from the pic you had posted on facebook. Lemme know if you need any machining done, and I'll see what I can do for ya. I've got access to just about any equipment, but we're so buried at work so finding time to get to it is a bit of a challenge.
 
Title: Re: My new project!
Post by: two-smoker on Jan 01, 2011, 04:11:23
I appreciate it, Jake! Right now my main concern is getting the bike roadworthy... After that- well, I've got big plans.... 
Title: Re: My new project! Heretofore called 3 The Hard Way.
Post by: two-smoker on Jan 17, 2011, 03:33:42
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/Mobile%20Uploads/2011-01-13_230326.jpg)(http://i961.photobucket.com/albums/ae98/BurnOutSX4/Mobile%20Uploads/2011-01-13_123233.jpg) just a quick progress report. Started work on my seat hump/reserve tank. Still need to weld in the new filler.(http://i961.photobucket.com/albums/ae98/BurnOutSX4/Mobile%20Uploads/2011-01-13_123614.jpg)
Title: Re: My new project! Heretofore called 3 The Hard Way.
Post by: CrescentSon on Jan 17, 2011, 05:56:08
Looks crazy cool TS. There is a lot of potential in that $500 score.
Title: Re: Project 3 The Hard Way.
Post by: two-smoker on Feb 03, 2011, 01:14:38
Project 3 the Hard Way is on a little hiatus for a bit thanks to this damn snowstorm, but just a little update, I am in the process of ordering some Mikunis for it. I wish I had some pictures or more to say, but, alas I don't. Be patient!
Title: Re: My new project! Heretofore called 3 The Hard Way.
Post by: two-smoker on Feb 18, 2011, 03:08:34
Alright! I'll be hitting it hard this weekend. I purchased a pair of Mikuni's from DCC today, but they're back-ordered til mid march, so I'm going to make sure everything else is ship-shape before they get here. I've gotta swap front ends with one of the parts bikes, and fix some cracked cases.... Battery, oil change.... Hmmm.... I'm looking forward to this a lot less now... Lol.
Title: Project 3 the Hard Way: rearsets.
Post by: two-smoker on Mar 09, 2011, 21:30:24
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-03-09_191237.jpg) These are rearsets culled from an '87 Hurricane 600 I had laying around.... They will be finding a new home on my Yamaha. I have also started cutting down the stock seat to fit my seat hump/reserve tank. Progress is slow because I don't have heat in the shop my bike is in, but that won't matter when my carbs finally show up. I've decided to try using the motor in the bike to start with, but I'm going to refurbish one of the motors in the parts bikes to take its place in time. Questions?
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Mar 21, 2011, 16:15:21
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-03-21_124413.jpg)
Took a paper template of my bike's frame to cut out the frame for making my fiberglass seat section. Then, cut out the mesh frame, which I will be welding to my seat hump/reserve tank before fiberglassing over the screen.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-03-21_130811.jpg)
Title: Re: Project 3 the Hard Way
Post by: saywhat on Mar 21, 2011, 16:35:17
Are you still looking for a manual, I have a PDF version of the factory manual if that might be helpful.
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Mar 21, 2011, 21:08:35
If it's the repair manual, not the owners manual, I'd greatly appreciate it! Burnoutra43@yahoo.com if you'd be willing to email me that pdf. Thanks!
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Mar 22, 2011, 01:32:49
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-03-21_232448.jpg)
My first officially completed part! Picked up a pair of BMX bicycle pedals, and welded one into the end of my original kick start leg, after cutting off the original foot bar. Should match my motocross footpegs really well. Sweet! Also, just for fun, I replaced the cheap plastic bearing cover with a Brazilian 50 cent piece I had laying around.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-03-24_010228.jpg)
Kinda hard to see in this shot, but  it's what I got.
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Mar 26, 2011, 14:13:58
A little off topic, but just a question for allll you guys. In case my motor is shit on this bike, I'm considering using the motor from a GS500e as a contingency plan.  But I still want a kick starter. Anyone know how difficult it'd be to fit the kicker and right side case cover from a GS400 to the GS500 motor? Thanks.
Title: Re: Project 3 the Hard Way
Post by: VonYinzer on Mar 26, 2011, 18:35:55
Id bet its near impossible without a massive amount of custom machine work.
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Mar 26, 2011, 21:58:32
I just figured, they're the same engine family(the GS400 became the GS425, then the GS450, and eventually the GS500), so maybe the innards are close enough to pull it off. Anyone been inside both a GS400 and a GS500? Are they close?
Title: Re: Project 3 the Hard Way
Post by: SrgtBear on Apr 03, 2011, 22:15:19
Great find man.  It's great to see so many more TX500 and XS500's popping up on here lately regardless of their poor reputation with those values.  Like everyone said,  just make sure you adjust them.  Take your time.  It will pay off.  And let me tell you these engines sound so great and pull so well.  Your gonna love it.

Here is the manual if anyone needs it:  TX500 Service Manual
http://www.dotheton.com/downloads/Yamaha_TX500_500A_Service_Manual.pdf (http://www.dotheton.com/forum/../downloads/Yamaha_TX500_500A_Service_Manual.pdf)

Check out my build.  Let me know if you need any help.

Keep up the good work!
Title: Re: Project 3 the Hard Way- TX500
Post by: two-smoker on Apr 04, 2011, 01:44:52
Hey thanks a lot SrgtBear! I did get a copy of the Yamaha factory service manual printed out, but it's always good to share. I've read your whole build thread, btw, and it's truly a big compliment that you approve of my project.
Title: Re: Project 3 the Hard Way-New Pictures!
Post by: two-smoker on Apr 07, 2011, 01:14:46
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/SANY0007.jpg)
The new (to me) tank I picked up off another forum member. It's a 78 XS500 tank. I think the style suits a cafe racer much better than the original did. If you look closely, you will also notice something new just underneath said tank.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/SANY0006.jpg) My new Mikuni VM30's! If you look even closer, you'll see a bit of green at the flange. That is a glimpse at the adapters I made to bring the OD up to the same as the original carbs.
I still need to replace the right side engine cover (it's cracked) and the kickstarter return spring. I'm also working on the seat section. It appears it will not fit without removing some bits. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/SANY0008-1.jpg)
You can see the issue here. No worries. I have a new die grinder.  :)
Title: Re: Project 3 the Hard Way- RUNNING!
Post by: two-smoker on Apr 08, 2011, 21:20:05
Don't know if this link will work, but if it does.... Check it! I got the dirty bitch running!

http://www.youtube.com/watch?feature=youtube_gdata_player&v=UtNVQAS1aFc (http://www.youtube.com/watch?feature=youtube_gdata_player&v=UtNVQAS1aFc)
Title: Re: Project 3 the Hard Way
Post by: two-smoker on Apr 12, 2011, 11:46:33
Well, looks like this is going to go down a slightly different path than intended. For those that don't  already know, I lost my job. Of course, that means my budget is shot, and I can't do all the things I wanted. At least not right away. So, I'll be doing what I can with the parts I already have (having 2 parts bikes is a blessing in this case) and trying to use all the extra time I now have to good effect. 
Oh, and if anyone wants a 74 TX500 parts bike, let me know. I'm taking all the original locks off my bike and putting them on the better parts bike, and putting the other motor in as well, so it'll be complete minus title. Just saying.
Title: Re: Project 3 the Hard Way
Post by: SrgtBear on Apr 12, 2011, 12:37:19
I am sorry to hear about the job buddy.  I may want some of those parts if they are up for sale.  I could probably use an undamaged swing arm.  I wanted to powder coat mine but I painted it instead because it had a few small dents which i filled in.  It's probably gonna get chipped away at eventually.

I also need the rubber grommets for the side covers.  I have a few but I can't locate a couple of the top pieces and specific missing the bottom piece that they snap into.

 
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Apr 26, 2011, 18:49:34
I don't have any pictures this time around, but just a little update. Since the parts bike I'm keeping didn't have keys, I transferred all the locks and guages to it from my bike. I wasn't going to use them anyway. Clipons are on order from DCC, as well as throttle assembly, grips, and headlight ears in black. Also, I snagged a second throttle cable off a junkyard bike, since for some reason the one that came with my Mikunis hangs up a little.
So she's half dis-assembled again, awaiting new parts, after which I'll finish the wiring and chop up the frame a little to better suit my needs. No more centerstand, no seat hinges or lock, shortening the rear subframe about 8 inches.
Oh, and I've got a surprise in store regarding my ignition... Since I HATE points... Lol. Prepare to be amazed!
Title: Re: Project 3 the Hard Way
Post by: saywhat on Apr 26, 2011, 18:59:01
I'm excited to see what happens with the ignition, I would love to dump my points system when the time comes.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on May 12, 2011, 23:29:24
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-05-12152228.jpg)
Just a small update. I went ahead and lopped off the rear frame section so I could finalize placement of my new seat section/reserve tank and get cracking on the fiber glass. I also managed to make a trade with another forum member so I am now running VM32's, as opposed to the previous 30's. (thanks AimSmall)
 I'm mostly stuck right now waiting on parts from DCC (clipons, throttle assembly and grips, headlight ears) so progress is limited, but I'm doing what I can. I'm on the hunt for a CBR600f3 right front rotor and a FZ600 master cylinder so I can finish my front brake setup, but it's not like I can install it without bars anyway.... Other than that, I'm ready to buy the parts for my own design of electronic ignition, but unemployment doesn't pay well enough to let me do that yet... On the plus side, it should only cost around 70 bucks and a little fettling, so it beats Newtronic in both cost and percieved reliability.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on May 18, 2011, 14:05:35
Pertronix or other car systems have been used in the past.  I often modify DYNA S systems as long as I can get them at the right price (cheap).  I have also used systems off GS twins and 4s which are usually quite cheap.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on May 18, 2011, 21:32:53
Yeah, you got me... I was planning on using some Pertronix components. After some closer inspection I'm not as sure it would fit. I'm thinking compufire might work a little better. We'll see now that I've got a spare timing plate and advance mechanism to work with.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on May 23, 2011, 22:20:02
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-05-23171221.jpg)
Stone guard for the headlight.
I gotta say, being out of work sucks. Not much I can do without a steady paycheck.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-05-23171314.jpg)
I did lop off the passenger peg loops quick while I was detabbing the frame. I won't be using them. As a matter of fact, they were kind of in the way of the rearset assemblies. A keen eye will also notice I removed the main pegs and shortened the motor mount bolt to compensate. It was in the way of the shift linkage.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on May 25, 2011, 20:15:44
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-05-25170356.jpg)
I think this will be somewhat more effective than the stock rotor.... Well, once I get my new Nissin two-piston caliper mounted.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 10, 2011, 01:36:41
Okay, I realize it's been a while since I made an update, but I'm unemployed, so what can I do? I've been spending most of my time fucking around with the parts bike I gave my buddy. I even managed to procure a title for it. In my opinion, the bike was done.... But the new owner took a liking to some of my mods, and tried to emulate. So now his bike looks good, but won't run. I guess he doesn't subscribe to the "if it ain't broke don't fix it" school of thought. And I'm STILL waiting for the clipons I ordered from DCC on April 20. Also, I was supposed to pick up a caliper adaptor on Saturday at the   AHRMA races in Elkhart Lake, but the blueprint I made up apparently had some errors. So my machinist buddy had to start over, and it won't be ready. Boo. That's my update.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Jun 10, 2011, 13:14:49
Hang in there Thom, and keep talking to people about what you do and what you're good at and work will find you - but you have to keep chasing it so it can catch you.  Like women - if you're desperate they sense it and you lose out. When you appear not to be chasing it's easier to land one.

If you need some bike inspiration, we're about an hour south of you down 94.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 11, 2011, 00:45:33
Thanks Teazer. I appreciate the pep talk!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 13, 2011, 00:52:58
I was at the AHRMA races in Elkhart Lake this weekend, mostly for fun, partly for business, and I procured a few odds and ends. Pictures will follow.
My machinist buddy (kodiak on the forum) made an adaptor for me so I could use a CBR600f1 caliper on my stock forks with my FZR600 front rotor, and he brought the first attempt with him so I could check it on the bike to see if any changes need be made. Obviously, some changes DO need to be made, but on the whole it will work out famously when finished.
Also, I ran across a Ducati style fiberglass seat/tail in the swap meet area that I HAD to have. Thanks go out to my best friend Jake for helping me pay for it.
As an aside, Jake should be putting up a build thread of his own shortly. We now have a title for the parts bike I gave him, and after today's thrash session, it runs, too! So yeah, big ups!
Pics will be in my next post.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 13, 2011, 23:39:44
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-06-13204656.jpg)
Decided the Benelli mini-bike tank was not worth the work. Now I'm using this spiffy Ducati-style fiberglass seat. Also, I'm going with black case covers and valve cover. I'll paint the valve cover when I adjust the valves.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-06-13204528.jpg)
Test fit of the caliper and adaptor. Need to move the holes where it mounts to the fork down 3mm, and add some material at the caliper.
Oh, and I got an e-mail from Dime City today. Now it will be mid JULY before they can get my clipons sent out. I said enough is enough. I want a refund and I'm get a set off E bay. They'll only take a week.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: sparkymoto on Jun 20, 2011, 20:38:18
Do you need 35mm clip-ons for that Yammy? I can give you a deal on an extra set I have. They were for my t500 but I went with a modern USD front end. Let me know.


The project is looking good man. Keep at it.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: Juggernaut on Jun 21, 2011, 00:57:29
Hey two-smoker, where did you get that ducati style seat from? It looks to be the perfect length for me. Did you shorten the seat pan?
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 21, 2011, 02:30:16
Sparkymoto: I appreciate the offer, but it turns out I had ordered the wrong size in the first place. My forks are 34mm. So this whole debacle was a good excuse to order the right stuff.
juggernaut: I got the seat from a swap meet vendor at the AHRMA races in Elkhart Lake last weekend. It was the only one he had, and it's got some flaws. I didn't need to shorten it, I just tucked about an inch or so under the back of the tank.
Thanks for the encouragement!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jun 23, 2011, 23:16:44
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/1308882220959.jpg)My clipons finally showed up! I'm so jazzed. Maybe now I can get some actual work done on this sucker! They're so sweet... Even the bars are aluminum!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: SrgtBear on Jun 24, 2011, 09:04:31
very nice
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jul 13, 2011, 05:36:00
It's been a while with no progress. I got the clipons on the bike, but that's it. The guy who owns the building my bike is stored in needed to work on a big old Ford, and it takes up the whole shop, plus has my bike pinned against a wall. Hopefully I'll be able to get at it on Thursday, maybe at least get the throttle done and start on the wiring. That is all.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jul 28, 2011, 01:39:36
Well, I STILL can't get at my bike, but I wanted to have a record of my "wish list" of parts and mods, so I have a reference point when I start work again.
1) Frame to be painted hammertone silver. (Done)
2) Wrenchmonkees style little round taillight. (Done.) Most likely from Cycle X.
3)Pertronix Ignitor parts to make my own electronic ignition I ended up buying a Newtronic unit made for the bike also planning to use Ford coil-on-plug coils.
4) I'd LOVE to lace up some 17" black, aluminum rims with stainless spokes. Not likely, but it is a "wish" list. I managed to lace up some aluminum 18s using stainless spokes and a YZ250 rear hub. Bonzer. Also took care of the next item on the list.
5) I'd also like to ditch the drum brake out back. Maybe a GS hub or something could work. Not a high priority.  DONE

6) New fork seals DONEand Timken neck bearings.
7) A GS500e motor for when I inevitably blow this one up. ;)  (Ended up finding a Rebel 450 and did some motor mods.)
8  ) Guages and indicators of some sort. An Acewell if I win the lottery. Chrome minis and little LEDs in the meantime. DONE Got the Acewell!
9) High pipes! I'll settle for reverse megs in the meantime. I found a nicer 2-into-1 that I'll be modifying, also to look like three Wrenchmonkees bike.
10) Braided stainless brake hose up front. DONE
11) Paint the fork lowers to match whatever my final color for the tins will be. I'm thinking a nice olive green gloss with gold flake... Maybe with dark green scallops.
12) Rear shocks. At least 14 1/4" long. I'd like Redwing Hammerheads in spite of their relatively low performance. I've got some RFY piggybacks, but they're too long... Still working on a solution.
13) Pingel petcocks. I need some kind of reserve now that I'm not using the seat hump tank.
14) DCC LED bar-end signals.
15) new chain and sprockets.
16) paint wheels black.
17) bronze swingarm bushings.
18) An RD350 six-speed trans.
I'll add more as I get there.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Aug 18, 2011, 01:07:36
there's a '78 XS500 on Craigslist for 600 bucks and I have no money! DAMMIT! I'd have loved to get my hands on a later motor.....
Title: Re: Project 3 the Hard Way- I'M BACK BITCHES!
Post by: two-smoker on Aug 22, 2011, 21:04:18
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-08-22163142.jpg)
I finally was able to get into the shop to work on the bike. Today's progress: hand controls. Dig the waffle grips! I also was able to complete the throttle cable assembly.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-08-22163653.jpg)
I also decided to mock up the shift side rearset assembly. Final mounting will require some welding- the top mount needs to sit in the "v" of the frame. I also need to replace the footpegs. As you can see, the rubber is gone, and they're ugly besides. I've decided on some old motocross "bear trap" pegs, since they match the BMX pedal kicker.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-08-22163348.jpg)
As you can see, I haven't gotten the broken stud out for the right exhaust yet. I'm sure it's also obvious that the shop is a mess. Lol.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-08-22163313.jpg)
I need to get a 24" braided line made up for the front brake yet, and do the wiring for the ignition and lights. Oooooh, and I've got the seat section at home so I can spray it and foam it. Picked up some closed-cell from home depot. Gonna spray bomb the fiberglass metallic black to match the tank for now. I'll change the color after I work all the mechanical bugs out. Slow progress is still progress!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Aug 29, 2011, 12:22:57
I am so pissed! I ordered my bear-trap pegs off of ebay and got an empty box! Damn you USPS!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Aug 29, 2011, 12:48:24
Are you sure those coil over plugs will work?  I seem to recall that on bikes at least they are really low resistance and are designed to work with electronic ignitions with short dwell time.  I don't know if that applies to the Ford coils you are talking about.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Aug 29, 2011, 16:39:24
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-08-29131539.jpg)
Just added a little black to the palette... I think it looks good.
Teazer, no i'm not certain the Ford coils will work, but I figure I can always add resistance, kind of like the old Chevy method of putting an inline resistor in the coil circuit. I will be running an electronic ignition, so I'm pretty confident I can get away with it.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 02, 2011, 01:07:40
Okay, so I've been toying with an idea for a while, and I guess I need an informed opinion from someone who's had a TX500 motor apart. I used to own a few CB450's, and they didn't use balance shafts. They vibrated, but not to the extent of shedding random parts from the bike or anything.
So.... Yeah. Since the balance shafts in these bikes need so much attention, i'm considering removing mine entirely. Or, at the very least, removing the chain so it doesn't spin. Actually, the second is more likely, since it requires less work. (the balance shaft weighs, what, 8 pounds? Think of the effect of removing 8 pounds from the flywheel and you may understand why i'm considering it.) I'm not going to attempt it without some more knowledge, though.
To all the more knowledgeable fellas, will having the balance shaft stationary cause carnage through lack of clearance with other internal parts? Has anyone else tried it? I know i'm insane, but I'm seriously curious about the possibility.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: MotorbikeBruno on Sep 02, 2011, 13:16:41
I had that year TX and I'm not sure if I would get rid of anything labeled for "balancing" something.  I think of ceiling fan blades , wheels etc....a few grams means a lot...and 8lbs was probably put there for a decent reason....

With that said, I've happened to have owned many a failed motorbikes from yamaha...like the Yamaha Vision....so I can't tell you that it WAS truly put there for a reason  ;D   but I'd still be worried about what might happen if it was just "swinging around in there" heh.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 04, 2011, 11:41:46
Well, I appreciate the input. Of course, the idea is to STOP the balancer shaft "swinging around in there". It does serve a purpose, obviously, but that purpose is rider comfort. Which I have little interest in. My concern is: if the balancer isn't moving, will something else swinging around in there hit it? It a sizeable chunk of steel.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Sep 04, 2011, 12:10:23
Before I forget, GSXR stick coils are around 1 ohm primary 13ohms secondary - just as a reference point.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 04, 2011, 13:42:32
Ha! I get so used to repurposing car parts I forget about bikes... Yes yes, gsxr....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 06, 2011, 17:33:15
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-09-04205134.jpg)
After I bolted up the new caliper adaptor, I noticed a flaw.... Can you see it? The caliper is rotated too far forward. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-09-04210429.jpg)
 In the second picture, you see how far off my design was, with the caliper in the proper relation with the rotor. I suppose I can't complain too much, since the first draft was done in cardboard.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-09-04213752.jpg)
 Oh well. At least it's a correctable problem. She's such a pretty bike. I'd hate to screw up so bad I have to quit... Still having issues with the exhaust though. I cant seem to get that damn broken stud out of the head... The welder and a nut is the only method I haven't tried yet.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Sep 15, 2011, 20:50:39
Balance shaft: I completely removed the entire shaft,bearings,chain, sprocket,the entire system.I was shocked how little difference it made in vibration!! I forgot how much weight it was,but it was a bunch.My opinion,remove it.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 16, 2011, 00:41:42
Jimmer, I appreciate the input. I have doubts about my ability to remove the whole balance shaft assembly, though. Do you think if I just removed the drive chain for the balancer something else spinning around in there would hit it?  It's not that I don't want to tear this motor down, because I really do, and of course that would be the time to find out. Now, I don't want to do a half ass job, but with my situation financially (lost a good job, got a crappy one, have no money) I can't afford the things I'd need to do a proper build.  So, yeah, I'm trying to half-ass my way through this build... Ugh, I'm ashamed...
Oh, I read your TX/XS500 blog. I really like your approach to the oil filter availability problem. And, did you build that two-stroke powered XS500? That looks like a real hairy ride...
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Sep 16, 2011, 01:08:19
You can remove the balancer assy for very little,if any cost.I will donate a case gasket if yours tears.The hardest[and it really isn't much of a deal] is pulling the clutch basket to get the last bearing out.Yes, you can leave the balancer in and just remove the chain,nothing will crash.But why not spend a little extra time and ditch a few pounds? Yes, I slapped the CR500 motor in my spare chassis.It worked fantastic,except to run 1/4mile I had to gear it way too tall and it really killed the holeshot.1st gear was too tall and 5th gear was still too short.But it was fast as heck inbetween! My best pass was 12.32ish@108/109mph.It had stock porting,big Mikuni,Jemco pipe.It would have been awesome with a 6 speed.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Sep 16, 2011, 01:09:42
Oh,you just go in it from the sides,you can leave the motor in the chassis.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 18, 2011, 20:40:43
That's good news... You know, maybe I will try it. I've gotta open the right side up as it is, to fix my bungling of the kick start mechanism, so I suppose it's worth a shot.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 21, 2011, 02:21:59
Well, I got a start on the wiring yesterday. So far, I replaced the original glass fuse with a modern blade-type, and tested my new ignition switch with the key start, and it does crank over with the key. Of course, this made my mistakes with the kick start mechanism more apparent, so before I finish the wiring I'm going to re-open the right side of the engine and give it one last try before I just give up on having a kick starter. It doesn't really work that well with rearsets, anyway, but I really want one if I can make it work. When I open up the cases, I'm going to see if I can get the balancer out, and eliminate it if I can, as well.
I still plan on going with electronic ignition, but I may try to get the bike running again with the points, just so I can ride it and see where the bugs are. I'll go electronic after I get everything else sorted. And I'm STILL having issues getting that broken exhaust stud out of the head. I tried two different styles of stud removers, and it just snapped further down. There's about a half inch still exposed now. So on my next day off, I'm breaking out the welder. If that doesn't work, I'm drilling it out, and noone wants that.
I've been trying to find another alternative to the factory oil filter as well. I took the adaptor/housing/whatever off the junk motor I scrapped, and I've been going around bike shops in town to see if a different company makes a filter that will work. No luck so far.
T hat's my update for today. Later.
TS
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Sep 21, 2011, 16:10:17
Wasn't there a an adapter available that converts it to "normal" ie commercially available filters.  Search for that - maybe it was Joe the Powder guy JRK that mentioned it on his build.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 22, 2011, 01:11:39
The operative word there is "was". Yamaha made a kit back in the day that used the filter off such bikes as the FZ600, if I'm not mistaken. Turns out, a filter from a Hyundai Tiburon v6 will fit as well, even better, as a matter of fact, but those adaptors are thin on the ground. So for now, I'm trying to find another filter that fits the stock adaptor. Should that fail, I could also make something up like Joe did, and put an inline cooler in the circuit as well. 
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Sep 23, 2011, 18:38:01
Check out my filter write up at xs500blogspot.com   Scroll back to the older posts. There are no other filters that fit,OEM or crappy EMGO that leak are the choices.Or something like my filter setup.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Sep 24, 2011, 00:44:43
Jimmer, I really like the way you dealt with the oil filter issue, and I may go that route. I just wanted to check  if a (relatively) modern Suzuki Honda or Kawasaki might use a filter that would work. You are right, nothing.  But I had to try.
TS
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 15, 2011, 00:31:53
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-14125836.jpg)
Successfully attached the Honda Hurricane rearsets today. I even got the shift linkage working, if a little too low. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-14124026.jpg)
 I'm still trying to work out the best way to maker a linkage for the rear brake, but I've got an idea to use the splines from the original brake pedal, and weld a tab to it. Hard to describe, you'll see it when it's done.
I did manage to also get the front brake operational, as well. The new caliper adaptor is on it's way, but for now, the hydraulic portion is completed. I tried the "weld a nut on method" to extract my broken exhaust stud, but I didn't have a good weld. I'll try it again Monday. If that fails, I'll try to drill and tap. If THAT fails, I'll be looking for a GS500e motor.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: kodiak on Oct 16, 2011, 18:08:13
if all else fails, take the head off and find a local machine shop with a tap burner.... they can burn that stud right out and I'm sure it wouldn't cost much... would take them less than 5 minutes
 
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 16, 2011, 23:03:18
Yeah, Jake- I've been toying with that too.... Mainly because I'd like to get my hands on a later head. I know how often these early ones crack. Of course, that's why I'm avoiding removing it. The bike runs. I don't want to take it apart and find out I can't put it back together. Delaying the inevitable, y' know?
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 17, 2011, 15:17:32
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-17120316.jpg)
Well, here is as far as I can go without more money. There are a few little things I can still work on yet, like wiring and installing fork seals, because I either already have the necessary parts, or I can procure them for little to no cash.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-17120529.jpg)
I like this view the best. Very aggressive. I'd like it more if I could afford the taillight I want. I've decided on the Shot Glass Taillight from After Hours Choppers. I realize paying $150 for a taillight is excessive, and wanting to when you're broke is worse, but I don't know of a cooler taillight out there, and it would fit in with the style of the bike so well.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-17120225.jpg)
Oh, yeah, I did do some stuff today. I welded in my new battery tray. And I discovered that I need to find a way to move the kickstand tang forward about an inch when the stand is up. I hit it with my toes when I'm shifting. The front brake is operational, even if the caliper needs to be oriented differently. (this is being addressed) I'm still doing little stuff here and there, but this is pretty much what she's going to look like.
She needs some more love, but I'm really happy with the overall look.
I need to go talk to some people at Manpower about getting into a factory where an old friend of mine works, and if I succeed at that, I'll be bringing in enough cash to keep going.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 18, 2011, 12:22:27
man really like the front brake set up you did ! anyway you can post the final dimensions for the hanger? and that seat is a airtek Duc92up seat /tail got the same one on my XS.. really like what your doing man and hope you find some work to get her up and running.....(http://i1104.photobucket.com/albums/h331/dreadrock1/seat2.jpg)
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 18, 2011, 13:15:47
Haha! Great minds think alike, eh? My seat is definitely not an Airtech piece, but it looks the part, so who cares, right? The Ducati seat shape worked well with the Yamaha tank.
As far as the dimensions on the final revision of the caliper bracket, I don't have them yet. But Kodiak (see above posts) is the machinist. I'm just an artist in the medium of cast-off parts. If he's willing to share, it's his baby. I made the original piece out of cardboard, and sent him my (wrong) measurements. And made a lot of changes since. So I can't say for sure where they ended up. I can say that I'm using an '89 FZR600 rotor and an '87 CBR600 caliper, and the caliper needs to mount 15mm inboard of the original fork mounts. The rest I kind of forgot....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: kodiak on Oct 18, 2011, 13:46:28
I have no problems sharing.... i still have the mastercam file, i'll try to drop some dimensioning on it and see if i can find a way to post it when i get some spare time at work.
 
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 18, 2011, 18:28:58
Well your bike is looking killer man airtek seat or not still has sweet lines ! was looking for a cool set up for the front brakes might have to talk to Kodiak about a hanger  when i get there !
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 20, 2011, 12:01:58
Fate is messing with me.... There is a 91 GS500e on Craigslist Milwaukee for $300. If I had 300 bucks, I'd be on it like flies. Running or not... Is it obvious I don't want to tear down my motor?
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 24, 2011, 20:54:01
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-24175204.jpg)
Sometimes the solution to a problem is simpler than you imagined. In this case, not so much, but it is something I felt stupid for not thinking of... I kind of forgot that I had a 9,000 mile motor sitting outside the shop. That is, until I began clearing out my tools in preparation to bring the bike home, and saw it sitting there. Soooooooo... I took the head off. This is what I found inside. But who cares? Barring a couple of stuck exhaust valves and the plugs broken off flush, it'll come in quite handy. So much for my problem with the broken exhaust stud!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 24, 2011, 22:53:24
looks like someone burnt soup !
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 24, 2011, 23:14:26
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2011-10-24210003.jpg)
 Here's the other side of the coin. The plugs are broken off, and three exhaust valves were stuck (it's two now). But it's better than trying to drill out the exhaust stud on what I recently discovered is a cracked head. Off to the machine shop!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 24, 2011, 23:19:24
was that the good engine out of the 3 ? or is that the one you want to use ? nice thing is lets you build some  performance into it !
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 25, 2011, 00:56:44
These last shots are the lowest-mileage motor of the 3.  It had 9600 miles on it when it was put in storage in 1975. Hadn't run since. When I gave the bike to my buddy, the first thing he did was snap off the plugs flush with the head. So I swapped in the last motor available. Mine is still the original that came in it from the factory. Since neither of us was interested (at the time) in taking the head off to fix it, it sat outside.
I still don't want to take the head off my bike, since I'm lacking a few tools (like a camchain breaker or installer) necessary to reassemble it. I also need to find a good head gasket. But it would seem to be the most logical way to fix the problem I'm having with the broken exhaust stud on the right cylinder, plus I get to inspect the motor's innards. Oh, and the original head is cracked, so there's that, too.
A good full-radius valve job would be nice, as well.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 25, 2011, 10:22:49
dont know but can the head be fixed? im still learning what can and cant be done and never heard anyone say they can be fixed just that you need to keep a eye on it . well good luck man !
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 25, 2011, 11:44:12
I suppose it depends on how bad the cracks get, but I know guys that have welded up aluminum heads before. I'm not super worried about the original head because the other one isn't cracked. Not that it doesn't need work, but it doesn't need welding, so the rest is just cake.
Title: Did I say "until I get a better job"?
Post by: two-smoker on Oct 27, 2011, 14:48:15
I got some very good news today- I've been offered my old job back! This is a HUGE shot in the arm for this project. It'll be a few months before I'm comfortable spending money on anything but the necessities, but I had to share the good fortune! I hope y'all can be patient while I get my life back together...
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: sxecafe on Oct 27, 2011, 14:56:06
Congrats, man! Sure that is a relief.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: JustinLonghorn on Oct 27, 2011, 16:08:30
Hell yeah man! Congrats on the new/old gig.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: DreadRock on Oct 27, 2011, 17:15:07
Thats great to hear man !
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: MotorbikeBruno on Oct 30, 2011, 18:11:37
Awesome! Congrats!  Glad to hear some GOOD news once and a while!  Can't wait for more on this, I've enjoyed the build so far.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Oct 31, 2011, 01:18:05
I want to thank you guys for the encouragement. I'm thinking I'm not going to do too much this winter on the bike, but I'll post pics of any parts I collect before it gets warm again. The garage I have the bike stored in is not heated, so patience is the order of the day. I can't paint it, I don't have the camchain tool so I can replace the head, and the wiring will take weeks, which I will NOT do in the cold. I'm kind of glad, though. The more I force myself to take things slow, the better the final result will be, right?
Oh- I don't suppose anyone knows where I can find a 2-into 1 pipe? They're pretty thin on the ground.  :-\
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Nov 11, 2011, 17:44:01
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/007-15.jpg)
Yeah, I know I said I wouldn't be comfortable spending a ton of cash just yet, but ctluba had these great gold-and-black piggyback shocks for sale on the forum, and the price was right. Soooooooo.... Yeah.
I picked up all the necessities for re-doing the harness as well. Shrinkwrap, terminals, even a really nice fuse box for blade-type fuses. Oh, and I got an AGM battery. My final draft of the caliper carrier is ready, I have new pads for the caliper, all kinds of good stuff that has to wait until spring. Maybe I can at least take my spare head to the machine shop.....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: MotorbikeBruno on Nov 14, 2011, 14:33:46
Those are some sexy shocks my friend!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Nov 15, 2011, 03:43:25
Wait til you see them on the bike! I can't believe my good fortune coming across these...
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: IncorpoRated X on Nov 15, 2011, 10:07:06
http://www.ebay.com/itm/170574045325?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649


You could have paid $100 shipped for them brand new.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Nov 17, 2011, 22:33:22
So, I have a bit of a dilemma... I had resigned myself to making my own ignition from bits from the Pertronix kit for VW's, but I received an email today from Newtronic saying the kit for the TX/XS500 is available to preorder. For double the price. I have to admit, I'm tempted. Just fit it and quit it, right? Before I make up my mind, what do y'all think? I had heard the Newtronic units were not so reliable.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Nov 17, 2011, 22:37:46
Incorpiratedx, thanks for the info, I'm okay with 10 bucks more for a forum member. Plus, the shocks I got are the length (15 plus inches) I wanted for my bike. The ones you pointed out were shorter than my stock shocks.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: saywhat on Nov 18, 2011, 02:15:50
Looking good, I'm always checking your thread for encouragement
:) Cheers
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: cafecustom720 on Nov 18, 2011, 02:19:28
The bike is looking good. You mentioned earlier you wanted a bit of a wrenchmonkees look and with that tank and tail I think you've got it going on.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Nov 19, 2011, 10:25:14
So, I have a bit of a dilemma... I had resigned myself to making my own ignition from bits from the Pertronix kit for VW's, but I received an email today from Newtronic saying the kit for the TX/XS500 is available to preorder. For double the price. I have to admit, I'm tempted. Just fit it and quit it, right? Before I make up my mind, what do y'all think? I had heard the Newtronic units were not so reliable.
Buy the Newtronics!!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Nov 19, 2011, 11:07:28
I'd buy a Dyna S and modify teh backing plate, but if you are not comfortable with changing a brand new expensive part, go with the Newtronics.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Nov 20, 2011, 05:45:08
Well, I guess that's my answer... Lol.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Dec 01, 2011, 19:10:42
I just wanted to post a quick update, even though I haven't been working on the bike. I heard back from Newtronic, and there are 4 ignition units available... I want one, but being so close to Christmas, I don't have the extra cash right now. And that really sucks. I wrote back, and the fella I have been corresponding with said just to write when I'm ready, so I'm going to just hope one will still be available after all the Holiday hoopla is over with.
Of course, if none are available then, that's just an omen that I should make my own... So we'll see! (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/downloadfile-2.jpg) Ain't it pretty?
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Jan 30, 2012, 03:34:57
It has been a while! I haven't actually been working on the bike, but I did start amassing parts again. Starting with a new oil filter adaptor I found on ebay! Why bother you may ask? Because it's the Yamaha adaptor to fit an updated filter, which means I can run to any auto parts store and pick up a standard PH6607 filter whenever I need one, instead of scouring Ebay for NOS filters from Yamaha. I also called up the machine shop about my replacement head, and I'll be dropping it off on Wednesday.  That's all for now... But spring is right around the corner!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 01, 2012, 21:28:39
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-01-31220950.jpg) just another look at the head I'm planning on using. With the better light, you can see one of the stuck valves, plus the broken spark plugs still in the holes. I dropped it off at the machine shop this morning, along with a spare clutch cable to have shortened. I'll get a cal in about a week if they were able to fix the head or not. If not, I'll be looking for a later, one- piece head.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: saywhat on Feb 02, 2012, 02:43:37
Good to see you back in action, I need to update my xs500 thread too.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 02, 2012, 06:07:27
Oh, yeah, glad to be back!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 03, 2012, 03:38:39
My oil filter adaptor showed up today! Can you spot the difference? (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-02-02172119.jpg)
I have to admit, I was a little scared when I opened the package, because without a side-by-side comparison it's hard to see. It's maybe an 1/8th inch bigger in diameter, and the threads are only 2mm smaller. But it is what I was after!
Also, I found a beat-up 2 into 1 header on Ebay for $100 with free shipping. I would much rather buy something thrashed because I plan on cutting it up, anyway. After I saw the Wrenchmonkees XS500 I knew that THAT was what I wanted my exhaust to look like. So that's what I'm doing.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 04, 2012, 09:29:47
This is what I have in mind for the exhaust. Mine will just be black. My 2-into-1 rusty header should be on it's way to me. After I chop off the original megaphone and strip the rust off, I'll see if I can mount an old Supertrapp. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/XS500_18.jpg)
Yes I know, I wanted high pipes, but plans change.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 07, 2012, 03:42:58
I heard back from the machine shop today. The good news, is the broken spark plugs have been extracted. Bad news? ALL the valves are stuck, and my trip to the solvent tank ruined the valve seals. I suppose that isn't too big an issue, since the motor in the bike is still a good, complete runner (barring the crack in the head and the broken exhaust stud). I just hoped I wouldn't have to do that. But beggars can't be choosers. The head isn't cracked, and all I have to do is move the good valves and seals from my bike to the new head, and bolt the sucker on. Once I figure out how to remove the old head without ruining the cam chain.....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: jimmer on Feb 07, 2012, 20:10:42
You grind the master link which is either a different color or the rivets will look slightly different.Grind the mushroom of the rivet off and press it out.You will then need a new rivet.If you look around you can find them cheap.Do not buy one of those $45 links! Also loosen the chain tensionioner nut,push the tensioner down to release the chain tension, and snug the nut up with the chain in the  loose position.Do that right before you pull the link out.Also you can find aftermarket viton seals very reasonable,and they are WAY cheaper then OEM.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 07, 2012, 21:01:39
Thanks for the insight! My manual says the same thing about the tensioner, but there aren't any pictures to show where it is.... Or even a description. It should be obvious, I know, but as you could probably surmise from my handle, I don't work on four-strokes that often. Do I need to remove a cover to find the tensioner bolt or something? Also, the manual mentions "Yamaha special tool" such and such to remove and replace the link. Can I just use any old chain riveter?
edit: nevermind on the tensioner- I read a little further ahead in the manual and found it. And that's also where the manual specified how to replace the link. Duh! I toopid!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 24, 2012, 10:07:48
Alright, the weather hasn't been super cooperative in regards to working on the bike, but I have slowly been procuring some necessary items. I'm waiting on a head gasket right now, and after I receive it, I'll at least be able to remove the old head and install the new one, even if I won't be able to reconnect the cam chain. Valve seals are installed, I just need to hit the sucker with a wire brush to remove the deposits from the combustion chambers. (the valves are unstuck and moving free, now.) I'm toying with  the idea of painting the head black before I install it, but I'm not convinced it'll go with the look I want. I was just going to paint the cam cover initially.
The only cam chain link I found was 55 bucks plus shipping, and I'm hesitant to pay that, no matter how rare it might be. It's just a master link! A tiny little piece of hardened steel, not gold! If anyone has info on where I can get one cheaper, I'd appreciate it.
 Oh, and my fiancee and I found out she's pregnant! Completely off topic, I know, but it's super good news. We really didn't plan on it, and the timing is a little off, but who's ever ready, right? Cash will be even tighter, but it's all worth it. Maybe I can pass this sucker down to my kid, if I ever finish!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 24, 2012, 17:48:08
Genius ideas in my sleep! Random, unnecessary, little details having nothing at all to do with the big problems I'm having with the motor, but so cool I had to share!
I've been wracking my brain about how I was going to cover my seat, since I don't have a sewing machine, and I'm not really good with one anyway. In my dreams, the answer came to me! I bought a bottle of Flex Seal (the stuff on TV) to fix my rabbit's litter box (galvanized steel that rusted through) and it occurred to me after using it, I can just shape the foam, and spray it with Flex Seal! The stuff goes on like spray paint, it's flexible, and clings like nothing I've ever seen. I couldn't even grind it off from the area where it oversprayed. It's waterproof too!  Perfect to cover a motorcycle seat with.  It even has a nice, textured look. All I need to do is mask off the areas I don't want covered, and spray away! So simple it's genius.
Also, I came up with a good idea on how to plumb in an oil cooler. The back of the head on these bikes has an external oil feed line that attaches on both ends like a banjo bolt. I figure, why not actually use a pair of banjo bolts, with barbed fittings, and run the cooler lines right up the back, over the head, and to the middle of the frame, in front of the motor? That will keep them nice and tucked, out of harm's way, and still allow me to cool the oil going to the head. It may even be an advantage over cooling the main oil feed, since the cooling will be more localized to the head. It will also give me about a half quart of extra capacity.
Oooooh yeah, I can't forget- I am going to try and combine my two ideas for the seat hump. I love the look of the Ducati style seat, but I still want  a reserve tank there. So I'm going to hide the Bennelli tank under the Ducati seat. Benefit being, I don't have to do any body work on the Bennelli tank. Plus I still get my extra range. I'll just nestle it down low enough that it fits under the fiberglass cowl. Clearance won't be an issue, since I'm raising the rear end 4 inches.
Alright, I'm done ranting now. Carry on!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: sxecafe on Feb 24, 2012, 19:24:40
HA! Its A Handy Man, In a CAN! Good Idea!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: IronSpade on Feb 25, 2012, 18:59:08
Two-Smoker, my name is Travis and I own Iron Spade Cycles. I build a lot of Yamaha RD350's and other two stroke road bikes into cafe's. I too am building a TX500 right now for a client. I don't suppose you'd want to do a little horse trading of some engine parts for maybe a leather seat cover for your Ducati seat? Something like the one I did for Marty Mc Fly's CB350F I built last year? Hit me up, maybe we can work out a deal. Here is a picture just to jog your memory...

I can be reached directly at ironspadecycles@hotmail.com Thanks buddy. Talk soon Travis
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 26, 2012, 09:34:15
Travis; I don't know what engine parts you need, but I have to say, I am in short supply. I've got a right side cover with some damage, and 4 exhaust pipes, and my head with the broken exhaust stud. Everything I've got that I don't need personally is in pretty rough shape. I mostly got rid of most of my extra stuff last year, to the local cycle salvage yard. They do have some complete late model XS500 engines there, though. It's Milwaukee Cycle, previously Milwaukee Cycle Salvage, under different owners. I'm sure they would be more help than me.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: IronSpade on Feb 26, 2012, 10:18:41
I really just need a valve cover, as one of the little ears snapped off from the over tightening from the previous owner. I will most likely just weld on a piece of aluminum and drill a new hole but if I could find one that someone would let go of for cheap that would still be easier. No worries, if you decide you want a regular seat cover let me know. I'm not a professional upholsterer but every seat cover I do is in leather with a foam backer stitched in. A few more jobs and I'll justify buying a $1200 walking foot upholstering sewing machine. Truth is I probably have 3-4 more seats to do this year so the machine really will be necessary just don't have the cash at the moment.

No worries. Tanks for the reply. Later Travis
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 26, 2012, 10:28:24
Hey, no problem, and the seat on that 350 is pretty good work.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 26, 2012, 11:01:48
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/SANY0008.jpg)

I just wanted to post a pic of my first cafe racer. It's the blue Suzuki in the front right of this picture. I built the little GT380 starting in 1995. This pic was in '98, about 2 years before I actually considered it "finished".  I rode it until 2001 when I had my right index finger mangled in a machine at work, and couldn't ride for years. It was "stolen" by a co-worker who intended to buy it, but never paid. I admit, it's a crappy pic, but it is the only one I have.  The final iteration had no fairing, but mostly looked the same, including the super-long shocks. I made my own rearsets with "GP" shift, laced a 17" rim to the stock hub up front, ran a Yamaha Radian swingarm, and had a CBR1000 master cylinder for the original front caliper, with braided steel line. The forks were reversed, with the caliper behind the forks on the left instead of on the front on the right and I ran clubmans. Front rotor was drilled, and I had a Boyer ignition, and Wirges chambers. I also made my own guage setup, with a little 2" electronic tach for an automotive v6 application(which only worked because, the Boyer ignition fires all 3 coils at once) and some micro LED's. I kept the original gear position indicator, because I  thought it was cool. Oh, and the Lucas tail light. Sounds pretty standard now, but I did this in the 90's. Ah! Memories.... I still have the title! The only thing I wanted, but never got to do, on this bike is the Ducati style seat I'm using now. So that's my little homage to my lost little smoker.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: rewindstuff on Feb 29, 2012, 16:29:37
where did you get the new oil filter plate? and what new filter will it take?
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Feb 29, 2012, 19:28:48
I got lucky and found one on Ebay. It's an old Yamaha factory part, made originally as part of a kit to use a newer Yamaha filter, after the original filters wete discontinued. It's been long discontinued, as well, so the only way to get one is to find a used one, or maybe if an old dealer had some still sitting on the shelf. The guy selling it had just pulled it off a junk motor, and don't know it didn't come that way. It happens to fit a filter for Hyundai V6's, Fram number PH6607, but it was designed to use the filter for a newer model 4-cylinder Yamaha. The problem with that, is the filter it uses required you to remove the generator cover to fit or remove it- whence the Hyundai filter.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 07, 2012, 17:20:05
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/SANY0002.jpg)

Showing fitment of the new head gasket. I'm kind of irked that it was shipped in an envelope instead of a box, cuz it got bent in shipping. Hopefully I can still use it.... As you may notice, I have not cleaned the combustion chambers yet. I'm waiting to do that at the same time as:
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/SANY0001.jpg)

 Here is a quick shot of my new rusty 2-into-one as well. I'm going to strip the rust off with my die grinder and wire brush, and chop off the original megaphone. After I paint it high-heat black, I'm going to either fit the old Supertrapp off the Hurricane 600 I've been pirating parts from (preferable), or get a reverse megaphone (if the Hurricane has been scrapped already). Since I've removed the passenger peg loops from my frame, I'm also planning to hang it from one of the tabs for the centerstand (which is getting removed anyway). One less tab I have to cut off.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 13, 2012, 22:42:41
Tired of dodgy updates with no real progress? So am I! So here is a little something new. Parts actually getting put on the bike!

 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-13172546.jpg)

New shocks installed. For comparison :
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-13164246.jpg)

 This is only moments earlier, with original shocks fitted. Note the air gap under the back wheel. Now, the centerstand no longer reaches the ground. This, of course, brings up new problems. The side stand is now too short as well, and the chain rubs on the top of the swingarm. Oh, and the gas tank is tilted forward do far the petcocks are no longer at the lowest point. Easy enough to fix, but the shocks were only supposed to be an inch longer than stock. So.... Unexpected. Oh well. They look cool.
 You may also have noticed the seat removed in the "after" shot, as well as the can of Flex Seal on the ground in front of the bike. Reason?
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-13172557.jpg)
Booyah! Getting ready to spray on the new cover. Once the glue dries on the built-up piece at the front, we'll see if I'm a genius, or just crazy. I'm going for the former.  ;)

 And last, but not least, version 3.0 of my caliper adaptor to fit a Honda Hurricane 600 caliper to TX500 forks using an FZR600 rotor. The result?
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-13173026.jpg)
We have a winner. The prize is a new set of EBC pads. Woo hoo!
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 14, 2012, 09:35:06
The Flex Seal did not work as expected..... It covered the foam very well, and looks good, but unfortunately stays rather sticky when applied to foam. On metal or fiber glass it dries hard to the touch, but the foam must soak up and hold onto the solvent that keeps the stuff liquid. Hopefully it will continue to dry over the next couple days. If not, I'll have to pick up some new foam and cover the seat in vinyl after all.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: IronSpade on Mar 14, 2012, 12:00:48
My offer still stands, if you want me to make you a seat cover. Where you at? PM me so we can discuss it a little more. The seat foam I'd suggest is at you local sporting goods store get the softest black foam exercise mat. Use the thickest you can find and use as many layers as it take to make the seat foam about 1-1/2 to 2 inches thick. Use an electric turkey carving knife to shape the foam, the pro's use a course hacksaw blade welded to a jigsaw blade. I've never tried that method but I'm sure it works well to. If you like I can do the foam for you as I have a reasonable source. Use 3M glue for foam to hold the layers together and when finished with the cover glue the cover to the foam and seat base, again if you'd like I can do all that for you in either vinyl or leather. If you've got an old leather jacket you cant wear anymore that could work well and look cool to boot.

How is your seat base attached to the frame? if your using fasteners that are effectively under the seat foam you might want the seat foam and cover to be removable, in that case a fiberglass under-seat pan must be made and the seat cover will need either snaps or a velcro attachment to the actual seat base. Again I can do all that for you if you'd like.

Hit me up. Talk soon, Travis....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 14, 2012, 18:23:28
Ironspade, I do appreciate the offer, but this is one of those things I need to do for myself. I have found a foam I really like, I just don't have the hang of shaping it yet. I used a bread knife for the first go-round, it works well, I just don't have the talent. It'll come with time. Stitching I do know well, though. I planned initially on using black denim, but I do a lot of foul weather riding and I don't like my ass getting soaked. I may just cover over the flex seal with material, now that the foam has been waterproofed. I haven't had a chance to check if it dried any more yet today, so that may become a moot point. Realistically, though, I'm going to plan to re-cover.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 15, 2012, 03:43:08
Well, the foam is officially dry to the touch, but it really looks like crap. I blame my lack of skill with shaping foam, and impatience.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-14170552.jpg)

Now that I know the stuff works, though, I'll be fixing this disaster. I'm going to trim the edges away with a razor, then use a softer foam with straight edges to fill it in. After that, I'll glue some thin packing foam over the top and re-spray. I just have to remember to apply thin coats.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 20, 2012, 19:42:10
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-20165307.jpg)
Fitted my exhaust for mockup purposes today. I didn't realize until now that it had a different routing than any other 2 into 1 that I've seen for the TX/XS500. It actually required the removal of the centerstand to fit. This was, of course, not a problem, as I had planned to remove it anyway.

(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-20165324.jpg)
 The masking tape is where I'm going to chop the muffler off. I was also thinking of shortening the horizontal pipes before the collector to make it look more like the exhaust on the wrenchmonkees bike. That would also allow me access to the inside of the pipes where three dents are, so I can pound them out. If I could photoshop, I'd do it, but I'm sure the idea isn't lost. You can also see part of the brake linkage I'm working on in this shot.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-20165339.jpg)
Here you can see one of the problems that arrose when I lifted the rear of the bike. The chain is trying to occupy the same space as the swingarm. I  will be fitting a nylon rub block.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-20171151.jpg)
 The other problem caused by lifting the back was that the kick stand became too short. Phase one of correcting that is this: I lowered the front as much as I possibly could. Phase two will be moving the kickstand toward the front of the the frame about 2 inches. The frame sits lower there. ( the stand also interferes with my shifter, so it will correct that too.)
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 23, 2012, 17:55:45
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-23154254.jpg)

 I'd say this is an improvement. I did a little shaping with a sanding cloth. Needs another coat, and done! And if it still looks like crap, I can always put a cover over it. Lol.
Of course, now I have to think about some proper paint.....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: teazer on Mar 24, 2012, 21:19:25
I could be wrong, but the rear looks too high and the front looks too low. Have you calculated the Rake and Trail in teh current configuration?

To run that much rear end droop, you will probably have to raise the motor in the frame to get a decent chain run. The front end looks scarey low, but that's easy to change.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Mar 25, 2012, 05:10:50
While I didn't take measurements of rake and trail, it's far less extreme than my GT380 was. The front end is exactly the height I wanted, but I might have to lift it back up another half inch, because the fender hits the frame at full compression. I don't want to admit it, but the back is too high. The shocks are at least an inch longer than the bike can tolerate, possibly more. I like them, and I don't want the hassle of trying to swap for shorter ones, so I'm going to make them work somehow. Probably a chain tensioner mounted to the swingarm.
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Apr 13, 2012, 03:45:13
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-03-31160039.jpg) Nothing much to report. We've had a lot going on this last month, and I haven't had time or desire to do anything with the bike. About the only thing bike related that has happened is I lost the key to the gas tank some time during the move. Guess I need to visit the locksmith....
Title: Re: Project 3 the Hard Way- 73 TX500
Post by: two-smoker on Apr 22, 2012, 19:36:09
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-04-16221330.jpg)
I finally got back to work on this sucker for a short while.... This is a shot of the pieces I started with, in an attempt to make my rearsets quirk with my kickstart and rear brake.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-04-22144734.jpg)
This is the right rearset assembly incorporating a linkage to operate the rear brake. I still need to get some heims and threaded rod to complete it. I did install some folding pegs.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-04-22144719.jpg) That, of course, was so this would work. I was going to heat the factory kicker and bend it into a "z", but a guy I work with decided it would be easier to make a whole new one out of 3/4" cold-rolled steel.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-04-22144656.jpg)
This is in the upright and folded position, where you can see it doesn't interfere with my leg placement. That's all for now!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 08, 2012, 07:55:20
It's hard to do much in the way of updates when I can't find time to work on the bike, but I've got the last Newtronic ignition in Australia on it's way to me in Milwaukee. Other than that, not much to report. I've gotta snag a cam chain riveting tool before I can go any further than I am. At this point the only change is the name- I've decided to call her "Shinjimei". The Japanese word for"fuck you". Have a nice day!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 08, 2012, 10:29:14
Your going to like that Newtronic set up man . I'm running one in my 500 and it mounted right up and when i went to start it the bike just backed fired. So like they said in the papers that came with it spin it 180 degrees and it fired right up . Will say well worth the money !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 08, 2012, 12:55:49
I really hope so... I ended up overdrafting my bank account to pay for it.... >:\
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 08, 2012, 13:09:59
Yea there a bit pricey but well worth it you'll like it im sure !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 09, 2012, 07:57:28
I'll like anything that lets me start my bike!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 16, 2012, 21:24:20
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/custom-ford-econoline-van-3.jpg)
inspiration for what I want to do with my paint...  The van is pretty much the same shape as my gas tank. Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 17, 2012, 10:52:57
You planning on doing the stripeing or just the color of the van ? And im not much for a van but cool looking ride for sure ! Did you get your Newtronic set-up working ?
Title: Re: Project Shinjimei- 73 TX500
Post by: JustinLonghorn on May 17, 2012, 11:31:22
That van is the cats pajamas, man! Doing your tank in those colors/design would be beautiful.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 17, 2012, 12:42:28
Thanks, guys! I'm planning on doing both the color and stripes. The Yamaha logo will be in relief. The frame will be silver hammertone. Dreadrock- the unit hadn't even shipped yet as of this morning... shouldn't take long to set up, though.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 17, 2012, 13:06:21
Cool yea seemed like it took forever for mine to show up but worth the wait . And sounds like its going to be a kick ass paint job man cant wait to see it !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 18, 2012, 16:34:20
Oh, yeah, I'm really looking forward to laying down some color. I've got the materials to spray the frame, but I want to finish up the motor work before I pull it out to do the job right.
I'll probably leave the tins black this year, since I'm blowing all my money in Disney with the family right now. Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2012, 07:58:15
Woo hoo! My ignition showed up! Can't wait to fit it.... Updates ASAP.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 25, 2012, 10:41:40
Sweet man should wire and bolt right up ! I did have to take a small file on the outside edge the main plate to help seat it snug, not much just a hair. On mine after hooking everything up went to fire it up and would just backfire . Just needed to go a 180 on the cam to get it right and set the Adv in the middle and fired right up . Good luck and cant wait to see a update !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2012, 14:37:30
Completely unrelated, but I also read on the TX/Xs500 forums that the 6-speed trans from the RD350 and 400 well fit in this motor with very little work... Looks like a new item on my wish list!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 25, 2012, 14:54:59
If you could please post the info you come up with would really like to see how that would work .
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2012, 22:34:30
Link to the page I found is http://www.xs500.proboards.com/index.cgi?board=general&action=display&thread=66&page=1  . The fella says the trans from the RD and the TX/XS500 are nearly identical. The 350 has the same ratios 1st though 5th with an overdrive 6th gear on top(what I want), the 400 has the same first gear ratio and sixth is the same as the 5th on the 500, meaning it's a closer-ratio box (what a racer would want)  The cases need to be clearanced internally slightly (about 1mm, a five minute job according to said gentleman) to clear a gear, and there is debate over wether the tach drive will work... But an electronic tach (like an Acewell gauge) negates the need.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2012, 23:30:57
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-05-25164234.jpg)
Haven't got too far with the ignition yet.... But I did get the oil filter adaptor and Autolite 6607 filter fitted, as well as the shortened clutch cable. While I have the cover off, time to drill some holes!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 28, 2012, 20:32:10
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/2012-05-28165146.jpg)
Just a little something I decided to do on a whim. Turns out the screen I picked wasn't quite big enough to cover the entire whole, but I'm not too concerned. Once I paint the cover again, it shouldn't be too noticeable. And if it is, Shinjimei! lol.
 Started on the ignition install as well. Got the rotor and pickups in, just need to get on all the wiring. Hopefully, that won't be too difficult, but after all the stuff I've removed, I'm sure it'll be a bear...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 30, 2012, 12:59:15
Alright, so I've been reading a lot of other build threads, and I've come to the conclusion that I've made a few errors.  My shocks are too long, my front end is too low. Direct and to the point. The front end is an easy fix, I need to poul the forks out to install the seals, so I'll just not push them down so far. The shocks.... Might get weird. I really REALLY like these shocks. Do I don't want to swap them for anything shorter, unless they're the same shocks (but shorter). Maybe I'll just relocate the shock mounts to lower the ass end a bit....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 30, 2012, 13:43:40
What size shocks are they ? Stock ones are around 12 + inches and i believe you dont want to add more then a inch to that . Also im running my front forks at a inch down from the top any more and the bike might get lil crazy at speed . See if that works for you befor picking up new shocks or making new shock mounts !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 30, 2012, 17:56:57
Hmm. My stock shocks measured 14". These are 16".  (I've verified by holding the old shocks next to the new ones that there is a 2 inch difference) I really wanted to get the rear end as high as I could, I just had no idea when I got the shocks how long I could go. The chain went slack, and it rubs both the top of the swingarm, and the top of the motor mount bolt that's under the filter/sprocket cover. If I drop it an inch, it'll take care of both issues.
 When I built my GT380 I ran shocks 3" longer than stock with no issues. I guess I got lucky with that bike, but I did run a Radian swingarm on it, which was an inch and a half longer than the stock one...
As far as the front goes, I have the forks pulled up as far as possible without bottoming on the lower tree at full compression. They will not be staying there, I just wanted to see what it would look like. I have to do the fork seals, anyway. (if I had some extra cash, I'd buy a modern front end- maybe an R1 inverted-and another Radian swingarm. Maybe some time down the road.)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 15, 2012, 22:12:09
I realize I've been a little lackadaisical... But I will have new updates soon. Thanks.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 28, 2012, 22:04:23
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0017-1.jpg)
Yes, I am still working on it! This is my new cylinder head, ready for install.... I swear, I WILL have more updates soon.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 11, 2012, 19:00:07
Finally, something with some substance! (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0019.jpg)

Here you see my temporary solution to mounting the taillight. With the bike sitting at its current height, I couldnt put it where I want it, but once I get the back end lifted to where I want, without interference, I'll make something permanent.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0021.jpg)
Here you see my cams and chain exposed, with the TDC timing marks aligned. I easily found the joint link with them incu this position, but something didn't seem right.... Upon further investigation I found that the timing marks for the ignition didn't match up with the timing marks for the cams. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0018.jpg)
This is how the timing should look, as the marks indicated the right cylinder was at TDC. Instead, with the cams aligned, I found...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0025.jpg)
The ignition timing actually looked like this.
I am 100% certain that someone was in this motor before me, so I can see two things that may have happened, both easily repaired while the head is off.
1) the cams are misaligned with actual TDC and the ignition marks are the ones I should use to time the motor.
2) the ignition drive is misaligned with actual TDC, and I should use the marks on the cams to re-set the igntion timing marks. Tentatively, I'm going to use the cam timing marks, as the ignition didn't seem to jive  with compression events while spinning the motor by hand...
We'll see soon enough!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 11, 2012, 19:57:05
Oh , just a quick FYI- I am not dragging this build out because I'm lazy. I am, mind you, but that isn't the reason this is taking its damn sweet time... I've had some serious personal issues this year, and I just want everyone to be aware building a bike hasn't exactly been priority one. I've set a lot of goals for myself on this project that have fallen by the wayside due to outside influence. That is no longer going to be an excuse...
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 13, 2012, 11:56:27
Hope all is well for you now man and as far as how long it  takes to build a bike it comes done to your time not anyone elses !!!
 My father build a old TR3 and when he pulled it in the shop i looked at it and said really dad what are you going to do with that ? Well he said make it mine and went about it the old way talking to people and reading as there wasnt internet around and after 7 years build one of the best TR3s in the area ! He didnt care what others thought a time frame should be he took his time and showed them !!!! So i would say your bike your life your time and F off everyone eles !!!!! keep it man !!!!!!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 20, 2012, 22:59:21
Thanks for the works of encouragement, dreadrock! Actually, my life is a total mess, but I'll survive. That's what i do! I thought of an easy way to determine what's up with my motor, in the meantime. I'm going to take out the plugs and stick a pen down the hole to touch the top of the piston, then spin the motor over. When the pen stops going up, I'm at tdc. That way I can see which marks are misaligned. My money's on the ignition....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 20, 2012, 23:15:39
Take a coat hang and cut a small part of and bend at one end . Take some blue tape or something to make on and marker. Use that to check it so you dont drop the pen in the motor  :( Also will let you know that both sides are the same ! Kind of i dont have the right tool for the job so going to make do  ;)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 23, 2012, 23:00:30
Well, I wasn't too worried about losing the pen in the motor, since the head is coming off any way, but that is something I hadn't thought of. Thanks again dreadrock!
Title: Re: Project Shinjimei- 73 TX500
Post by: MickyC on Sep 23, 2012, 23:27:38
swesome tx mate shame we dont get them for a decent price in aus saw one for sale for 6500 the other day and that was a total tear down job.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 25, 2012, 20:53:29
Deepwaterimports- that's nuts! Maybe these bikes are a little more sought after in Australia.... I don't know... But that would explain why that was the only place I could find a Newtronic ignition! The only place in the world where the supply exceeded demand.... If noone can afford the bike, who can afford parts?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 28, 2012, 23:13:16
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0032.jpg)
Well, it appears it was a good thing I checked which marks were accurate... The cams were set a tooth off . Amazing how stupid the last person to open this motor up must have been... The further I get into it, the more I find wrong. I mean, I can almost forgive the cams being timed wrong, but silicone on the head gasket? Ridiculous.
Of course, I am making my own mistakes as well. Apparently, there isn't enough room to remove the head while the engine is still in the frame. Guess I have to pull the sucker to finish this job...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Oct 17, 2012, 19:54:16
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0035.jpg)
Well, after weeks of procrastination, I finally got up the motivation to pull the motor and complete the head swap.... (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0036.jpg)
For the most part, the motor looks good. Obviously barring the silicone slathered on everything.... Bores are smooth, no corrosion. I need to get the valve springs moved over to the new head, and then I can reinstall.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0040.jpg)
Good thing I did this.... The old head is cracked between the exhaust valve seats and spark plug holes in four places. If you look carefully, you'll see them. On the right cylinder, the cracks extend a quarter inch up the spark plug hole! This bike was living on borrowed time....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0037.jpg)
While I have the motor out, though, I figured I'd take care of some other stuff. Like fixing this rat's nest.  I'll take the time and eliminate the unnecessary stuff from the harness while I update  a few things. I'll also finish de-tabbing the frame and paint it while everything's exposed. It gives me better access to the parts of the motor I haven't gotten clean yet, as well. Carry on!
Title: Re: Project Shinjimei- 73 TX500
Post by: rundown on Nov 08, 2012, 19:40:37
TwoSmoker;
I sure am grateful  for your lengthy build thread.  I am about to embark on a similar journey, but with a lot less skill and knowledge than you.  It is great to see what others have done and not to think everything will be be perfect or work the first time tried. 
Best wishes with the bike and getting your life sorted.
Steve
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 20, 2012, 21:41:14
I've been meaning to post an update for some time, but I suppose I'd have to accomplish something first, yes? The past few weeks I've been working on just cleaning up the exterior of the motor while I wait for various gasket components... Nothing worth posting pictures. Lol. The head gasket I purchased was apparently a later design, which requires a separate seal for the camchain tunnel, so I'm waiting for that... And I had to drill two little holes in the gasket as well, to match up with cooling holes in the cylinders and head. Frustrating, but necessary....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 25, 2012, 14:28:06
Well, I have stumbled into another delay! After discovering I need a second piece to go along with my head gasket, I figured I'd start putting the two pieces of the head together while I waited. I had set the bottom piece on top of the cylinders to stop dirt falling in the bores, and when I lifted it off, the cylinders came up off the cases with it. So, now I have to get a base gasket, and all the commensurate o-rings. I mention the o-rings, because, yet again, I find someone else wasn't so well-versed in the assembly process. There are orange o-rings at the bottom going around the cylinder liners, and not only were both torn, but one was actually both doubled up and pinched. Also, several of the little black ones around the cylinder studs were doubled up and pinched as well. No wonder I had so many leaks! Oh well, as always, I am doing work that will make the bike more reliable when it's back together. I have decided to pick up a complete gasket set off eBay and and do a "complete" tear-down. Especially since I accidentally dropped an o-ring down in the cases. Doh!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 25, 2012, 14:30:13
TwoSmoker;
I sure am grateful  for your lengthy build thread.  I am about to embark on a similar journey, but with a lot less skill and knowledge than you.  It is great to see what others have done and not to think everything will be be perfect or work the first time tried. 
Best wishes with the bike and getting your life sorted.
Steve
That's very kind of you to say! Thanks, I wish you well with your project as well!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 26, 2012, 23:02:22
 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0059.jpg)
What is this crap? I let this thing soak in solvent for two days, and this gunk didn't budge. The greasy crap between the fins, same story.... I might actually have to farm this part out... Hot tank? Soda blast? I got nothing.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Nov 27, 2012, 10:18:28
Maybe carbon build up ? But will say odd place for it if that whatit is  :o
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 27, 2012, 10:23:24
Yah, I think it's a combination of cooked oil and road grime settled into the ccooling passages. The damn thing leaked like a sieve from the head gasket, with all that silicone all over it..  I'm just amazed that the parts washer solvent didn't dissolve it.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Nov 30, 2012, 03:44:27
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0064.jpg)
Ammo pouches from a 1939 Mosin Nagant.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 03, 2012, 18:36:25
Looking at the bike today while trying to get the mounts for the ammo bag side covers brazed on, I was a little put off by the look of the rear frame section. The seat doesn't sit the way I want, and when I moved it into a position I liked, I realized what the problem was- the frame. Yep. The frame looks stupid. So I'm cutting off the whole back end behind where the tubes meet, including the upper shock mounts, and starting over. I'm undecided on wether I'm going to tilt the frame tubes up to match the angle of the seat, or just leave the tubes off, but it will allow me to relocate the shock mounts so I can use my fancy (and obnoxiously long) reservoir-type shocks without clearance or geometry issues. Pictures to follow.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 04, 2012, 22:26:50
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0067.jpg)
Okay. Here is what the seat looks like as it sits, laying directly on the frame. In this position, the cut off section of the rear tubes is covered by the seat, but in profile, the seat needs to sit up higher at the rear.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0068.jpg)
Like this. But that exposes the ugly frame. So...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0071.jpg)
Everything I have covered with my hand is getting removed. I may smooth it out, or add new tubes to follow the new angle of the seat. Either way, it allows me to do something I was thinking about anyway ...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0070.jpg) I'm going to relocate the upper shock mounts so I can utilize my reservoir shocks without raising the rear of the bike so much, as was the prblem I had with these shocks initially. (i realize this pic doesn't illustrate the end result as well as I'd like, but it was really hard to hold the shock in place while aiming the camera. Trust me, it works.)
This is all stuff I'm doing while the motor is out, waiting on gaskets for reassembly.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 18, 2012, 21:21:16
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0099.jpg) this, I'd say, is an improvement. Cleaning this little cooling/drainage passage took me days. It was completely clogged with a mixture of dirt and oil, even a copper washer from the brake system. (how it got there, I have no clue, but it was obviously there a long time.) Now I need to soda-blast between the fins on the cylinders, and I can use this stuff:
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0100.jpg)
Amazingly, Yamaha still has an ample supply of these o-rings that go around the bottoms of the cylinder liners. It helps that they were used on XS750s, 850s, and 1100s. I needed them, of course, because they were not included in this:
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0101.jpg)
I found this full gasket kit on eBay thanks to a fellow TX/XS500 forum member. The above o-rings were the only thing needed for a full rebuild that wasn't included. Of course, that means I will have many extra gaskets I can part with, so if you've got a 500 and need gaskets... I might be able to accommodate. I won't need the exhaust gaskets, nice viton valve seals,  oil filter mount gasket, or oil pan gasket for sure, once I finish assembly , I'll post what's left. Later!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 22, 2012, 13:43:51
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/282042_10200357552280629_103598141_n.jpg)
One of the new members of the TX/XS forum posted this pic of his build..... I had set my mind on retaining my stock front end, partly because of the work my buddy did making the adaptor to fit a Hurricane 600 caliper to it, while using an FZR600 rotor... But this may have changed my mind.....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Dec 23, 2012, 01:34:40
Mmm wonder what for front end  ?
Title: Re: Project Shinjimei- 73 TX500
Post by: kodiak on Dec 23, 2012, 01:49:31
Just lemme know what ya need me to machine to make it work, dude.

Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 23, 2012, 11:20:15
The front end in the picture is ZX6. I'd kinda like to keep it all Yamaha. If I do it....  R6...  Jake you're always a life saver in that regard.  I'd most likely need the newer stem machined to fit original bearings -  and for length. I'll keep ya posted! For right now it's a "file away for future reference " deal. No way I can afford it after I fix my car.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 26, 2012, 03:38:16
Today I went a little out on a limb,  and ordered an EX250 swingarm off eBay....  I know they'll fit an XS650 frame with little modification,  so I'm hoping that will be the case on the 500 frame as well. I looked up the pivot and axle diameters, and they look to be a match, so,  here's hoping! It was too cheap to pass up....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Dec 26, 2012, 10:19:10
Do i smell mono-shock ?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 26, 2012, 12:45:59
Dreadrock,  I'm still on the fence on that one.... I do like the idea,  but I put a bit of work into making my battery tray,  and I'd hate to have to cut it off to make room. And I do like the twin shocks.
That said...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/tx5002-23001-1.jpg)
I have looked into it. This fella used the stock swingarm and welded on his own brace/shock mount .
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/tx5002-23002-2.jpg)
it also looks like he completely re-did the rear frame section. I don't have a problem with that,  but like I said,  I have work into the path I've started on.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/tx5002-23005-2.jpg)
He started with a different plan.  If I'm going to do all the work of converting to a mono-shock, I want the ass end up a little higher. Nice to have another builder's work to reference, though. If when the swingarm arrives I discover I can fit a shock below my battery tray,  I might go that route. No matter what though, this IS the way i'm cutting off the rear frame tubes... Wait and see!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 30, 2012, 16:23:29
I've spent the past few days going over old posts on several forums looking for anything I might have missed, and I came across a few regarding the cracking of the head that I had forgotten about. The theory is that the original gasket material could act as an insulator, keeping heat localized near the hot exhaust valves or, more accurately, not allowing heat to naturally dissipate through several layers of gasket into the surrounding metal. I mention this because my engine is still dis-assembled while I procrastinate on getting the cylinders hot-tanked, and it affords me the opportunity to make improvements.
I'm impatient, but I'm (hopefully) not stupid. I already put the two pieces of the head together with a factory fiber gasket, but my new gasket kit has a nice metal and rubber one - I'm betting it's better. So I'll take that back apart. Now that I have two different styles of head gasket, I'm toying with using them to pattern a hybrid of the two and make one out of copper. I have access to material and a lazer cutter... Even If I don't know how to use it. That's the toying part. •﹏•
Copper head gasket=not likely.
That said,  the one in the kit (again) looks to be an update, with exposed aluminum between the cylinders,  molded in,  as well as several copper inserts at the locations for the cylinder studs, oil passages,  and locating dowels - also exposed. I know I spent good money on both pieces of the later style head gasket,  but I have better. I choose better.
Maybe now is a good time to look for an RD transmission..... 6 speeds is better than 5.... Even If I can't afford it.... And maybe it's time to cut off dead weight and reconsider some things I've already started, just in case something better is possible.  Mono-shock?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 30, 2012, 21:16:40
Oh Yeah - just for clarification; (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0103.jpg) this is what my bike looks like right now. Ha ha!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 07, 2013, 00:13:33
Well, I have my Ninja 250 swingarm. I will post pictures, but let's be honesty, it's January in Wisconsin.  I don't really feel motivated to work in the cold. Trust me when I say, though, I'm excited about the doors it opens for me. It is a little wider at the back, so I'll need to make up some new spaces for the wheel, but more importantly, it's a little longer. Updates to follow.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 14, 2013, 10:48:29
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0108.jpg)
Well,  I managed to brave the cold (12 frigging degrees ) long enough to remove the stock swingarm for a side-by-side comparison with the EX250 part. As expected, the pivot bolt is the same diameter,  so I'll be able to use the TX bit, after I narrow the pivot area of the Ex swinger about 6mm.  In this pic, you can see the extra length, as well. I was surprised to find the TX axle is a little bigger than the EX bit, though.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0111.jpg)
Of course, the new arm is a little wider at the rear, as well. The TX axle isn't quite long enough to work, so I figure I can use an EX axle,  and get new bearings to match the wheel to it, or I can have a new axle made up in the TX diameter, and mill out the axle plates to it. Horse apiece I guess...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 16, 2013, 09:37:27
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0113.jpg)
Just a pic showing how much wider the Ninja swingarm is at the axle. My buddy the machinist is working on spinning up a longer axle and some new spacers for me so the wheel will center in the same place. I will have the axle holes in the Ninja swingarm bored out to fit the new axle.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0116.jpg) just a quick-and-dirty print of the specs for the new axle.

(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0114.jpg)
Also, here I have the spacer tube from the EX pivot bolt set in front of the TX swingarm to illustrate how much the Ninja swingarm needs to be narrowed at the pivot. I'll have that done at the same time as the axle holes, and have shock mounts welded onto it as well. ( I have decided on twin shocks. If I change my mind, I'll still have the monoshock mounts on the swingarm.)
Tentatively, I've decided to use the drum brake on the rear. I will need to add a bracket for the torque arm, but I'll be leaving the one for the Ninja disc as well- again, in case I change my mind later.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jan 16, 2013, 10:10:07
Im likeing it sir ! How much longer is the new swinger from the old TX one ? Why not run rear disk on that bad boy ? Or even run the EX rear wheel and EX whole front end ? Not trying to 2nd guess just throwing ideas out there !!!! Keep at it man my shops cold but not that cold might want to stand infront of the frig to warm up  ;D
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 16, 2013, 10:32:40
Lol! Yeah, it's friggin cold out there! I just think the EX wheels are ugly, I would never use 16 inch wheels, and I've got a plan regarding the front end... The junkyard where I used to get stuff for my S12 Silvia has a crashed Hyosung GT650R.... I figure I can get the whole front end minus wheel for under $200. Inverted!
 I am seriously dead-set on spokes, but I would like to try and lace up a pair of wider alloy 18s... As far as using the drum out back, it's a pretty strong brake. In fact, it was considered "too powerful" in its day. Plus, I think it'll look really cool with some holes drilled in it and some brass-and-stainless mesh in the holes.
The EX swingarm is about an inch and a half longer than the TX piece. With my über-long shocks, it should help get the ass end down where I need it, since I can move the lower mounts back that much....
Title: Re: Project Shinjimei- 73 TX500
Post by: MotorbikeBruno on Jan 16, 2013, 15:25:20
This is one of my favorite projects to watch. Keep at it man. I hear you on the cold stuff I'm in that neighboring state to the West.  ;)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 19, 2013, 10:12:37
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0117.jpg)
Crappy pic, I know, but I just had to illustrate the new gussets I made up in anticipation of my rear frame modifications. If you look on the ledge behind the bike, you'll see the piece I'd rectangular tube I cut them off of.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0118.jpg)
While I was in the garage, I pulled the factory seals out of the Ninja swingarm to see how much material I had to work with to narrow the pivot. After I narrowed the center sleeve, I found:
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0119.jpg)
None. I have to shave all the way up to the bearings' outer surfaces. Thankfully, and strangely conveniently, the stock external seals from the TX fit perfectly on the EX swingarm..... Hopefully I don't have to take any material off the frame...
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jan 19, 2013, 12:53:24
Love when a plan comes together !  H. Smith the A-team !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 27, 2013, 21:31:00
Just doing my best to keep the thread alive... I'm waiting on my new rear axle from my machinist buddy.  (Made of 316 stainless.) I thought it was kinda weird that it measures 7/8" rather than metric, but I made the measurement myself, so I know that's what it is... Just curious. I'm sure a metric just happens to be identical, so no sense worrying. I'll be taking both swingarms to a local machinist this week (my buddy is in Chippewa Falls) to make the hybridizationhappen. Need to open the Ninja swingarm axle holes up to match the new/old axle, as well as narrow the pivot, and weld on the twin-shock mounts and drum brake torque arm mount, too.
 I see bradj's RD from hell, and I want some wheels like his, but I do like the look of the original drum hub.... No matter what, I'm gonna look at getting some aluminum rims and stainless spokes, though. Maybe not right away, but it's going to happen. For the time being, I will most likely just spray-bomb the stock stuff black to hide the rusty spokes....
I have the inverted front end in my sights, just waffling on pulling the trigger. I paid a good price for my aluminum clipons for the 34mm forks, and I picked up fork seals as well, and headlight mounts from DCC, plus the caliper and adaptor.... I want it, and I know it's going to happen...hell, it's even anodized the same color as my shocks! I just have to get over the pain of losing the cool stuff I already bought for the stock front end... Anybody want to buy my stuff? Lol.
Oh, and I bought a welder. Cheap harbor freight 90 amp flux wire. Maybe not good enough for the frame, but I can weld on the new muffler to my header. After I decide which one I want....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 04, 2013, 22:11:56
Well, I did it... I pulled the trigger and bought an inverted front end.... The long, slippery slope continues.... I guess new wheels will be a relatively small step from here. Lol. (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0121.jpg)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 06, 2013, 12:21:37
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0122.jpg)
Got the EX swingarm back from the machinist, and decided to make sure it fit. This is just a quick-and-dirty mockup of the lower shock mount location. ( The machinist was... Uncomfortable with doing the welding I wanted, so I'll just have to do it my Damn self.) With the upper mounts still at stock position, there is still a little more droop than I'd like, but that will be taken care of when I move the upper mounts.
Oh, and I have an 18 inch alloy rear rim and stainless spokes to fit a YZ 250 hub on order. Why you might ask? Wait and see!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 07, 2013, 22:47:45
 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0124.jpg)
Got my new front end today, and had to set it in there to see how it looks. Sexy! Amazingly enough, the Yamaha stem is an inch longer, AND larger in diameter- this is going to be a very easy swap.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 12, 2013, 17:33:35
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0012.jpg)
I decided to test fit my stock front wheel into the new forks to see how much work it would take to use my FZR rotor. Turns out to not be a huge issue. I need to stop at Bearings inc. and get some new bearings to match the wheel to the smaller Hyosung axle, and have my buddy whittle me up some spacers, but mostly looks like more smooth sailing. I'll see how long that lasts when I try fitting my caliper...
Oh, and I have rims and spokes on order. Black anodized 18" aluminum rims and stainless spokes. Turns out MikesXS has spoke sets made up for fitting an 18 to the front, so I bought a set. The 2.15" rim I originally ordered for the rear (with the YZ hub I bought from bradj) will be repurposed to used on the front, because I ordered a WM4.5 (2.75") rim from Buchanan's. Wide as I can go and not have a drop-center, which would require shorter spokes. I worry about the spoke angle, but I only paid 30 bucks for the rim, so if it doesn't work, at least I won't be out much. MikesXS has front 18's, if nothing else.
Damn, I am getting impatient!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 14, 2013, 09:38:33
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/IMAG0014-1.jpg)
Got some godies in the post today! Hub and spokes for the rear (and a caliper setup. Thanks bradj!), rim for the front. Waiting on front spokes and rear rim, then I'm a rotor, chain and sprockets away from having a roller again! Well, as soon as I weld the shock mounts onto  the swingarm...
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Feb 14, 2013, 18:33:56
Hope it all works for ya and im glad if made it safe
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Feb 14, 2013, 20:26:17
Was looking at the front end your using and man I really like it on the bike ! Might have to look into it down the road  ::)  will be looking forward to seeing the bike on its legs !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 14, 2013, 21:01:29
Thanks, Brad. This should work out killer.
Hey, can't beat 200 bucks for an inverted front end. Who cares if it's Korean? Lol. Have you seen the prices on Japanese stuff? Yeah, I'm looking forward to it, too! Getting closer....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 23, 2013, 09:24:33
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0016.jpg)
Got my rear rim today. So, as you can see, now I have both. I suppose I should get cracking. Being the impatient asshole I am, I ordered the rear rim from Buchanan's before I had the spokes in hand, so I had them drill for the smallest nipple size. Of course, that means I need to open the holes up a little.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0017.jpg)
I also burned in my new lower shock mounts.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0020.jpg)
This arrived a few days ago, too. My new rear loop. (thanks again, cafegoose!) [Forgive the crappy pic...] If you look close, you can see I welded in one of my gussets, too.
When I'm relocating the upper shock mounts, this will be added. That's all for now!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 11, 2013, 14:50:15
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0029.jpg)
I decided to try and lace up my own wheels. Initially it didn't go too well, since I started with the inner spokes instead of the outers... But I'm sure you'll agree, the end result is worth it!
Yeah, I got this shit.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 15, 2013, 20:21:33
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0030-1.jpg)
I just had to see how it looked in the swingarm.... I know, not an update, but I was excited, so reason enough. Carry on!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 02, 2013, 00:05:02
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0046.jpg)
I started trying to lace up the front wheel yesterday. It isn't going as well as the rear, but I'll make it work. The holes in the rim are angled wrong, so I'll have to fix that.
One thing that did turn out well was getting a front axle that fits both the old wheel and new forks.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0038.jpg)
Here is the original Yamaha axle and the Hyosung axle next to each other... Doesn't look very close, does it?
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0039.jpg)
Well, after spinning the end down 1mm and putting the Hyosung nut on, you get this. Ha!
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0040-1.jpg)
And as proof, here's the Yamaha axle in the Hyosung forks. success! Now I don't need conversion bearings or a new axle. Stick that in your pipe and smoke it!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 02, 2013, 09:45:56
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0041.jpg)
Oh, and my clipons finally showed up from Korea. My front end was bar-less. Now it won't be. Once I actually get the stems switched over... I have the Yamaha stem out of the tree, but it's freaking huge, so I have to bore out the hole in the Hyosung bottom clamp as big as I can, and spin the stem down besides. Should take a couple days for my guy at work to do it on our lathe. ( while I am perfectly capable, they don't trust us production workers to use the lathe) I need the trees done so I can get a measurement for the new front wheel spacers.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0036-1.jpg)
I pulled out my bodywork so I could figure out exactly where my rear hoop needs to go, as well. It's still a little too cold to finish that, but I have time. Plenty.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 02, 2013, 21:37:08
I don't suppose anybody is in dire need of a 2.15 by 18 rear rim for a YZ250? Cuz it isn't just drilled wrong for an XS front hub, bit dimpled wrong as well... The inner spokes worked, but the outers don't line up unless I angle them the wrong way. If nobody else wants it, I'm gonna drill the holes and they probably won't work and I'll end up buying another rim. Like, one that was made for this shit from MikesXS...
At least I only paid 30 bucks for the rim... If I end up destroying it I'll just say I paid an extra 30 for the spokes and forget about it.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 07, 2013, 13:55:30
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0047.jpg)
I managed to get the front wheel laced up, but I'm not happy with the result. I'm just going to buy a rim from MikesXS.
Title: Re: Project Shinjimei- 73 TX500
Post by: theroastedpeanut on Apr 07, 2013, 14:30:25
starting to look REAL NICE! I'm feeling that front end and swingarm swap... Keep up the good work! Ooh, and thank god you said no to that mini bike tank reservoir in the beginning, lol
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 07, 2013, 14:34:31
Lol. Yeah. That was a bad idea...or, it was a good idea that wouldn't work. I get a lot of those...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 09, 2013, 11:18:50
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0048.jpg)
You are looking at Hyosung trees with a Yamaha stem.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0049.jpg)
I love it when a plan comes together....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Apr 09, 2013, 12:53:09
Very nicely done now get them forks on the bike I want to see it happen !
Title: Re: Project Shinjimei- 73 TX500
Post by: teazer on Apr 09, 2013, 14:25:25
Have you check ALL-BALLS to see if there are bearings which will work with that stem and your frame? If there's nothing suitable, you could also look at making a new stem which would be fairly easy or turn down the lower end of that Yamaha stem to be a light press fit in the lower triple.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 09, 2013, 18:31:37
I actually bored out the trees to fit the Yamaha stem. Already done, and I have new bearings from All Balls, as well. The Hyosung stem is about an inch too short, otherwise I'd have just tried to get new bearings to match it up. It is smaller diameter, also, so this seemed like the logical way to go. Getting the Yamaha stem out was a bitch, though, because they weld around the perimeter at the bottom.
The new forks would already be on the bike if it was warm enough out to paint the frame. I'm going with a hammertone silver. I had thought about powdercoat, and I may still do it next year, but I have the paint, and I don't have the extra cash. Of course, I need to finish up the loop and upper shock mounts before I paint...
Title: Re: Project Shinjimei- 73 TX500
Post by: jimmer on Apr 09, 2013, 21:45:00
I used the whole front and all the rear minus the single shock setup from a YZ250 on my XS500 .I have it in the projects forum under "trackers"    http://www.dotheton.com/forum/index.php?topic=47906.msg531227#msg531227
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 09, 2013, 21:59:28
Jimmer, I saw that via a link on the TX/XS500 forum. Very cool. I like what you did with the exhaust, especially.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 16, 2013, 03:23:55
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0050.jpg)
I managed to get a few important things done today, thanks to the sudden warm weather... Here I demonstrate why I wanted to gusset the frame...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0051.jpg)
And, finally, my rear frame loop is attached! I am overjoyed. ;-)
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0052.jpg)
Even better, it fits exactly like I wanted! I knew I could do something right the first time. Lol. Of course, you'll notice I cut off the upper shock mounts. They are being relocated to the area under the weld attaching the loop. Not a huge change, but it's about an inch and a half further forward from the original location, which will pull the swingarm up to where I want it.
Now I need to relocate that damn kickstand....
Title: Re: Project Shinjimei- 73 TX500
Post by: MotorbikeBruno on Apr 16, 2013, 10:12:22
Woohoo!  Looks great! Doing it right the first time is always a plus!  8)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 16, 2013, 21:56:17
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0054.jpg)
Just because. I know it needs to come off again for paint, but I had to see it. Good thing I tried before final assembly. It turns out the lower bearing needs a spacer under it, or the lower tree contacts the bottom of the neck before the bearings are tight.
Now I hope I can get the bearing off without ruining it...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 17, 2013, 20:00:08
At closer inspection, I find my problem with the front end is both easier and more painful to fix. The original Yamaha lower tree had a raised area cast in, which worked as a spacer and a place to put a seal for the lower bearing. I pressed the stem into the new tree at the same distance as the old one, but the new tree is flat all the way across. This would be a huge problem, but actually, it turns out the lower race is recessed three sixteenths or so into the bottom of the neck.
While the original installation required the lower bearing to be spaced up to reach, if I did that, the stem would be that amount too short. Especially since the Timken neck bearings are taller, and add height at the top. So I'm going to have to remove the material below the race from the neck. Painful, but necessary.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Apr 17, 2013, 22:10:38
How's the lock to lock ? Any problem bar mounts hitting the tank ?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 17, 2013, 22:30:35
Actually it's pretty good. The factory steering stops match up to the trees pretty well. I suppose I could pinch my thumbs if I wasn't careful, but the bars don't actually hit. (the forks do come really close to the tank at the front, though...)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 23, 2013, 20:45:38
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0061.jpg)
I managed to finally get the shock mounts welded on, and finished welding the gussets all the way around... My rear rim is trued up as well, but I'm having some trouble trying to lace the front hub up to the new rim... Hopefully that's just down to me suffering from sleep deprivation and being delerious, and once I get caught up on my sleep it'll resolve itself.
That's it for now.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 27, 2013, 10:32:20
So.... After trying to lace up an 18 inch YZ250 rear rim, and then a high-shoulder 18 made for an XS650 front hub (which should be identical to my TX500 front hub) I have come to the conclusion that my spoke set, also from MikesXS, has to be mismatched. The inners are too long, and that leads me to believe they are for a 19 inch rim. I hope I am right, and that I can get the right ones in exchange..... (or alternately, that I'm just putting the Damn thing together wrong and don't have to exchange anything... )
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 29, 2013, 10:08:44
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0070-1.jpg)
FINALLY! With a little help from Big Rich, I was able to figure out what I was doing wrong, and finish lacing up my front wheel. It's all together, and all the spokes fit! Now I can move on.....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 02, 2013, 00:08:56
 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0071-1.jpg)
Today I busted out the grinder and got busy, starting with the neck. I used the stem from the Hyosung trees to protect the new lower race while I ground a little off the bottom. That way, the lower tree didn't bind on it when the bearings were tightened up. Mission successful. I also decided the fork lock needed to go. Now I just need to fill the hole it left....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0072.jpg)
Since I had the grinder out anyway, I removed the sidestand from its original location, so now I can put it where I need it, so it holds up the bike but doesn't get in the way of my shifter.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0073.jpg)
Just for shits and giggles, I cut a tray for my electrics out of 3/16" thick aluminum, while I was working....
That's all for now!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 02, 2013, 10:52:22
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0074.jpg)
Here's an example, just a little sample.....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 02, 2013, 10:57:41
Man your making me want to put usd forks on mine LOL looking real good man !!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 02, 2013, 11:05:06
Thanks, DreadRock! It means a lot coming from you, your bike is awesome... Seriously, if you get the itch to fit USD forks, the Hyosung forks are a really easy swap. Damn near made for it...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 16, 2013, 00:10:32
Not much to report, and no pictures right now, but I threw a coat of black paint on the swingarm, re-mounted my sidestand, and picked up some LED bar-end turn signals. Working on getting the frame painted, but not finished with prep yet. I have a few spots that need welding yet, and I ran out of wire, so maybe this weekend I'll start clinking some more paint. Later.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 19, 2013, 23:02:19
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0004.jpg)
I had my best friend over helping me out with the re-assembly of the engine yesterday. Things took an interesting turn. It seemed to be going well, but when I started torqueing down the cam caps the intake cam seized. As long as the last cap was loose, it was free, but once that last cap was tight, the cam wouldn't spin. After a very thourough examination, I discovered a speck of dirt. The cam and saddle are both galled. A little emery paper and all is good, right? Nope.
Cam still won't spin. Nearest I can tell, the cam must be bent, or the rockerbox tweaked, or something. So I'm just going to replace the whole bollocks. On the plus side, all the valve seals are now viton, and all the valves are lapped.
Stay tuned!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 26, 2013, 10:45:23
I bought a new camshaft to see if that was the root of my problem. It was..... Partially. The old intake cam locked up solid. This one spins, but it's still tight. So now a rockerbox assembly is on its way to me. If that doesn't solve the problem..... I'm burning the fucking thing.
In the meantime, I also bought a trucklight LED headlight, a Danmoto gauge.... And this: (http://i961.photobucket.com/albums/ae98/BurnOutSX4/IMAG0007.jpg)
I'm tired of having a bike in the garage and not being able to ride. So now I can. And when the TX is done, I can sell it.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 27, 2013, 10:13:32
O come on that's only pic your going to show ? Not fair man ....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 27, 2013, 11:22:56
Yeah, sorry.... The whole busted motor thing really got me down.... I'm so close, and I am just shy if making it out to Road America for the AHRMA races.... So I guess I wasn't in a picture-taking mood. When I pick the new bike up, I'll be sure and show it off.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 31, 2013, 11:20:35
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0016-1.jpg)
The Danmoto gauge arrived from China yesterday. Still waiting on the LED headlight lens, and the rockerbox.... And my front wheel is sitting at my brother's work, where I had the true done. Pretty much the only things I need to buy yet are tires/tubes/rim strips, and a muffler of some sort, and it's time to start final assembly. No hurry now, though, as I have the Hyosung sitting in the garage ready to ride. I missed my goal of the AHRMA races next weekend, so looks like I've got a new target of the Rockerbox gig in August. Cake.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 01, 2013, 03:39:48
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0017-1.jpg)
Got a few more things in the post today! First off, the new rockerbox assembly. As soon as I looked at it, I found out what the problem with the old one is- the cam caps are numbered to keep them from getting mixed up. Guess someone didn't get the memo. All the caps on the intake side are duplicates of the exhaust side.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0018-1.jpg)
My LED headlight bulb showed up, too. If it looks familiar, check out p71sohc's build thread and you'll know why. I'm thinking of trying to find an rxx/2 series BMW style shell for the headlight and gauge, but the stuff I've found is really  pricey.... Maybe I can find a fiberglass or plastic re-pop, or mold a gauge opening into my stock headlight shell...
That's it for now....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 08, 2013, 10:06:26
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/IMAG0025.jpg)
First time I've slowed down enough to take a pic of my new bike since I bought it. My buddy Jake, his fiance and I are up at the AHRMA races at Road America for the weekend... What a way to start the day. Progress on the Yamaha will continue when we get home.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jun 08, 2013, 10:17:23
So how's the power, brakes  on that thing ? Has a nice look about it I think !
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Jun 08, 2013, 10:30:25
Everything is looking rad my man
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 08, 2013, 13:58:49
Dreadrock, it's really nice. Power is great around town, but I gotta admit she struggles a little over 80..... Heh. Not that it should matter.... Braking is awesome, though. Suspension is really good, too. Obviously I like it, it's the same bike the front end for the Yamaha is off of. Lol.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0021-1.jpg)
I kinda forgot, too, I did have a little update... This is the LED headlight behind my rock guard...
Oh, and thanks brad! Lol. I like to think everything looks better from the seat....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 12, 2013, 20:59:53
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0026.jpg)
I took this pic while I was up at Elkhart because it gave me ideas on how to mount my headlight. Since my new forks are 51mm in diameter, I can't think of any better way than to make up a tubular (or round-bar) mount right off the trees. Let's see how this turns out....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 01, 2013, 09:38:37
Progress? Not much. I have been having some difficulty with the top-end. Seeing some Allen bolts in a location that required removal of the cams to reach, I mistakenly assumed (during dis-assembly) that they needed to come out to remove the Rockerbox assembly. So I removed the cams. Now, the intake cam seizes up when the caps are tightened. I purchased a new intake cam and a new Rockerbox. With the new cam, the problem is better, but stil not gone. When the timing marks are aligned, it gets tight, but it's free the rest of the rotation. I'm guessing that means I need to try the new Rockerbox assembly, but it didn't come with any hardware. So I have to get those bolts out from  under the cams, and I couldn't budge a few of them..... I guess I'll just have to make it work. Impact driver or something.
Seriously, it's very disheartening. I put a lot of work into getting the head ready, I'd hate to not be able to use it. But if that's the case, I am going straight for a GS500 motor.
Any of you XS/TX guys have any advice?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 24, 2013, 15:23:22
I've been a bit depressed about not being able to finish re-assembly of my motor, but as luck would have it, the local motorcycle salvage yard has a TX500 motor in stock. They won't break it apart, but for 120 bucks, I don't mind buying the whole thing. So.... Maybe I'll have a runner before winter.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jul 24, 2013, 15:27:04
Dam smoke wish you would of said something I have a spare motor ! If you need something just let me I know and ill see what I can do !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 24, 2013, 15:47:07
Well, shit, man! I didn't buy it yet! You got an early style or late style motor? I need the top part of the head, the cam and rocker housing, for the early motor. Hopefully one that's never been apart, because I've been through 3 rockerboxes and 4 sets of cams. It's like once they come apart, they won't go back together. If you've got a Rockerbox I'll pay!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jul 24, 2013, 16:26:05
Ill take a look tonight and get a number off the motor to make sure you can use it !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 24, 2013, 16:29:51
That's awesome, dreadrock. I'm pretty sure as long as it's a two-piece head they're all the same. My problems started when I removed the cams, so if there's any way you've got your cams still installed in that sucker, that would be what I'm looking for.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jul 24, 2013, 17:20:55
   Im almost sure I have that one and as for the motor being apart again it didn't look like it I was planning on using it for parts if needed . So I have no problem pulling it apart , ill get you a few pics befor I do just to be sure  ;D
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 24, 2013, 17:30:20
You would seriously be a lifesaver, man.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jul 24, 2013, 23:31:52
Number on motor is 1J3-008006 ? Did some looking and can't find anything on year and ill have pics for you tommrow !

Now that I think about it XS starts with 317 so I would think its a TX motor but not 100% sure !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 25, 2013, 03:32:05
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0089.jpg)
I was feeling unusually industrious today, so I finished all the miscellaneous welding I needed to do on the frame and have it a coat of hammertone silver. I finished the black paint on the swingarm, while I was at it. So... That's about it. Enjoy!
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Jul 26, 2013, 19:37:30
Number on motor is 1J3-008006 ? Did some looking and can't find anything on year and ill have pics for you tommrow !

Now that I think about it XS starts with 317 so I would think its a TX motor but not 100% sure !

That serial number is from a  mid-year 1976 XS500C...

The 371xxxxx 's are 73-74 TX500's and '75 XS500B's   

Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jul 26, 2013, 22:32:34
I was close just backwards  ::) thanks for the info Dean ..
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 26, 2013, 23:15:51
Hey, it's all help to me... Yeah, I wanted to try and use my original, low-mileage two-piece head, but even I have to admit that a later model head is a step up. Maybe I can get those viton seals off without wrecking them.....
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Jul 27, 2013, 00:24:57
I was close just backwards  ::) thanks for the info Dean ..

we know what you meant  ;D
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 28, 2013, 12:42:10
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0093.jpg)
I caused myself an interesting problem by using the Hyosung stem to protect the bearings from paint. I had to plug off the hole left from the original fork lock, and the Hyosung stem is smaller in diameter. That meant the plug was extended too far into the neck (as pictured above) and fouled on the Yamaha stem. So I had to stuff a dremel down in there and slooooowwwwly grind it down for clearance.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0094.jpg)
I just had to bolt on the bodywork and suspension to check out how it looks with the silver frame. I like it. In fact, with all the black accents, I like it enough I am considering retaining the stock color scheme instead of the heavy-flake green I was planning. We'll see.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 16, 2013, 06:10:41
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0107.jpg)
New parts! DCC stainless reverse meg....
Title: Re: Project Shinjimei- 73 TX500
Post by: SrgtBear on Aug 16, 2013, 08:10:12
I had a 2-2 with reverse mega phones on my xs500 when i started out.  Looked nice but i found it to be too loud.  the xs500 has a big piston.  Eventually i took them off and went to a 2-1 exhaust that came with the bike.  The 2-1 gave me better low end performance.  Try out what you have and if you dont like it try to find a 2-1, definitely makes the performance better for stop go.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 16, 2013, 08:36:39
Oh, you didn't see the 2-1 in my earlier post? One of the first things I bought. I just didn't like the wonky megaphone it came with, so I cut it off.
Title: Re: Project Shinjimei- 73 TX500
Post by: AceCR on Aug 16, 2013, 18:09:27
nice pipe
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 18, 2013, 21:37:19
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0108-1.jpg)
Back into it! Motor is (at last) back in one piece, thanks to DreadRock. Once I get some new tires, I'll have a roller, and I can set this bitch in the frame and nail down my sprocket spacing. Then I get to pull it out and soda-blast the motor and exhaust to prep for paint and remove all the oxidation. I can see the light at the end of the tunnel!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Aug 18, 2013, 21:49:16
Everything fit ok and cams are where they should be ? Glad to have helped sir and I like the black and gold !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 18, 2013, 22:14:26
The mounts for the air scoop are a little further apart, and the studs by the cam tunnel are a little long, so they need some different nuts to cinch down, but everything else worked fantastic. Well... Except I bungled and put the intake cam advanced one tooth, but  that's my mistake, and easily enough fixed. Yeah, the stock black and gold is growing on me.... We'll see. Anyone out there can Photoshop one of my old pics to see what the heavy-flake green would look like?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 19, 2013, 06:10:15
Oh, and I found out the tires I ordered (Kenda Retroactives) are on back order. No date available. So I'll most likely do the return and pick up some Heidenaus.
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Aug 19, 2013, 11:57:38
The mounts for the air scoop are a little further apart, and the studs by the cam tunnel are a little long, so they need some different nuts to cinch down, but everything else worked fantastic

I have an extra XS500 air scoop for you- looks like this:

 (http://i820.photobucket.com/albums/zz121/deanjarrett1/TX500%20Project%20Bike/DSCN2808_zps827b48fe.jpg) (http://s820.photobucket.com/user/deanjarrett1/media/TX500%20Project%20Bike/DSCN2808_zps827b48fe.jpg.html)
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Aug 19, 2013, 15:20:00
 When I was starting on mine I ordered wrong year scoop and got the bigger one . So I bent the tabs in and drilled hole thru the side to get at the Allens turned out great !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 19, 2013, 17:00:08
Damn, can't believe I didn't know there was a difference. What you want for that scoop, Dean?
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Aug 19, 2013, 19:49:55
Damn, can't believe I didn't know there was a difference. What you want for that scoop, Dean?
Yea, the later heads have the larger air scoop. How about the cost of shipping ,  plus any donation you would like to make to my rusty RD rescue project?  http://www.2strokeworld.com/forum/index.php?topic=17070.0

I'm  nearly finished with it, just out of $$  :(    ,  send me a pm 
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 22, 2013, 10:00:45
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0111-1.jpg)
Not a whole lot I can do until my wheels get back, but I thought I'd see what the exhaust would look like, with a little imagination. I think it's gonna be awesome!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 26, 2013, 21:29:33
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0121-1.jpg)
So I picked up a little present from my brother's work today....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0122-1.jpg)
...and it went a little something like this....  8)
It's on the ground again!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Aug 26, 2013, 22:15:25
Has a great stance man I Like It !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 26, 2013, 22:32:31
Thank you, Scott, I am rather pleased myself! I do kinda hope that with the weight of the motor she squats a little, though.... Otherwise I'll have to re-do the sidestand again- she leans waaaaaay over....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 28, 2013, 03:42:39
So, with some help from a member of the TX/XS500 forum, I discovered what I was doing wrong regarding the cam chain. Updates to follow.
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Aug 28, 2013, 10:18:43
Looks rad my man
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 28, 2013, 11:18:49
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0123-1.jpg)
Here it is! The offending link, now installed and riveted. Can't believe I didn't know that the tensioner can't be locked in place until the lock nut is backed waaayyy off.... Oh well. Problem solved!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 28, 2013, 11:21:19
Looks rad my man
Hey, thanks Brad! Glad you like!
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Aug 28, 2013, 11:36:24
What's not to like kool wheels kool swinger kool tank
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Aug 28, 2013, 15:51:44
Nice to see the head sorted out and back on   

It's all downhill after that one !   ;)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 30, 2013, 06:10:03
Well, getting on.... I'm getting started trimming up the harness for just the stuff I need, and I looked into how fuck going to wire up the Danmoto gauge, and I have questions. First, my neutral and oil pressure switches are ground-connect. Will that work? Next, how do I program the tach for number of cylinders? It's not in the instructions...
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Aug 30, 2013, 08:45:05
 Just to make sure we are looking at the same instructions and diagrams.. is this the model you have ?

danmoto model # SP-00002 ? it looks like the pic earlier in your thread....

http://www.danmoto.com/Ebay/Items/SP-00002/SP2.pdf

It looks like the diagram in the link is all you can get from them? ( mr google could not find anything more, even in Chinese )  Based on this, here is what I think:

The oil pressure and neutral senders to ground are MC industry standards so we should think that you just  connect them to your harness and go.

Now for the tachometer ... the schematic shows a single gray wire. If you already had an electronic tach, this would just plug right in , however you don't.  Because it looks like it is a direct plug in, it is highly unlikely that it is for an induction pick up of any kind and that's why there is not a option in the button menus to enter the number of cylinders. Because you have individual coils and no spark loss setup ( like a Honda four with 2 coils etc ) , I would think that you just connect the gray wire to the + lead on one coil  ( just make it L, #1 cyl to make it simple )


Are you running points or newtronics ?, (not sure it matters, yet just in case it would be good to know) 
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 30, 2013, 14:19:58
Thanks for the info! I was figuring on that with the tach, just wanted another opinion. Had no idea that ground contact was the standard, though, and that's very helpful, as well. Tried the link, and that looks like what came with the unit. Mine is the Acewell knock-off. Little round guy with two buttons. The instructions show how to set the speedometer for tire diameter, but nothing about the tach. I know on a car, it matters how many cylinders you have, but I suppose with individual coils it should work. Oh, and I'm running newtronic ignition. Now that I think about it, there may be a tach output.... Thanks again!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Aug 30, 2013, 14:24:38
  Oh, and I'm running newtronic ignition

 I sure hope you have better luck then me man you know my story about them !!!!!!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 30, 2013, 14:26:49
I do indeed! And so do I!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 02, 2013, 02:09:32
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0130.jpg)
Did a little work on the bike here, today. Started with finishing up the head swap. This bolt here caused one problem.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0129.jpg)
On the top is the original bolt from the old head, which was too short to work with the new head. Bottom is the bolt from a late- model, which is too long to work with the swap. So I made a trip to the hardware store and got one in between.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0128.jpg)
Next issue were these studs on the side by the cam tunnel. Yet again, too long, as the original stud to the left shows. Since I was at the hardware store, anyway, I picked up some regular hex nuts that would torque all the way down.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0132.jpg)
I also decided to finalize my mount for the turn-key ignition switch. It's a piece from the cleaning kit from the same 1939 Mosin-Nagant rifle the side pouches came from.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0131.jpg)
Aaaaaand then the big stuff. Can you tell I'm smiling? This was for exhaust mockup, but then I realized I needed to install the rearsets to nail it down.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0134.jpg)
So here it is. Rearsets installed, exhaust placement finalized. Digging it! The front wheel spacers are still in limbo, and the rear wheel needs to move about a quarter inch to the left, which was a surprise, but all in all, it's looking fabulous!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 02, 2013, 13:56:10
OUTSTANDING SIR !!!!!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 15, 2013, 18:31:11
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0135.jpg)
Not a whole lot to report... I bunged on the carbs and manifolds, only to realize my newly-installed petcock vacuum ports pointed right at the fins on the head, so ground out some clearance rather than move the nipples. I figure a little missing fin material is better than trying to move the nipples, or buying new manifolds. Other than that, just trying to work through the wiring harness.... Slowly....
Oh, and trying to figure out what I'm going to do regarding the headlight mounts... I found some that clamp onto the fork tubes, and that would be the easy way, but I kinda want to make my own. The naked Hyosungs use these two holes in the lower tree and have this complicated round-bar structure, but I thought maybe I could simplify the design and do this sort of ram's horn design.... I dunno. I'll figure it out. Not like I'm going to get to ride it this year, anyway.....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 18, 2013, 12:13:42
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0144.jpg)
I did a little work this morning before bed... Here shows that I now can shift gear without my foot fouling the sidestand.
 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0142.jpg)
Here you can see I have the rear wheel centered in the frame. (okay, it's offset to the right slightly, but it's close enough....)
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0137.jpg)
And the reason I say it's close enough is this: here I clamped a straight rod to the outside of the rear sprocket and lined it up with the front sprocket to see how close the alignment between them was. Mayhaps you can see it in this picture, but upon closer inspection.....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0140.jpg)
You can see that the rod lines up perfectly. Or, it will once I put the narrower 520 front sprocket on....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0146-1.jpg)
Aaaaand after I got bored with wheels and sprockets, I decided to nail down where my electrics will go. I am still undecided where to mount the new starter solenoid, but here's how the underseat area will look. I like it!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 18, 2013, 15:45:41
For the Starter solenoid maybe take a chunk of Aluminum and cut a L shape out of it and hang it next to ( cough  ::) ) the Newtronics unit ?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 18, 2013, 20:54:02
I think actually I'm going to put it to the side of the battery tray... I'm not using the original style solenoid, it grounds through its body, so I have to mount it somewhere that has a good ground. That aluminum tray is going to be rubber mounted. Plus, it's too big to fit under the seat with all the other stuff. Lol. Besides that, I am trying to get away with using as much of the original battery cables as I can. They won't reach.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Oct 09, 2013, 17:47:47
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0152.jpg)
Did some little stuff. Burned in my taillight/license plate mount. I'm trying to keep a little of the Ducati flavor from the seat section going.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0155.jpg)
I also drilled and tapped a place to mount the reservoir for the rear master, and settled where in mounting the starter solenoid. I realize I need to make a custom rear brake hose, and weld on some tabs. I also need to make up some kind of torque arm for the rear caliper. Baby steps.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Oct 10, 2013, 00:14:37
 How's the motor going ?

 On the tailight it fits the tail but maybe add a small fender from right under seat to where plate mount starts  ::)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Oct 10, 2013, 03:22:42
Funny you say that, Scott- I was on the fence about wether I was going to use a fender or not.
So far, everything seems good regarding the motor, but we'll see what happens once I get the ignition wired up.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Oct 14, 2013, 15:10:00
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0158.jpg)
I had the welder out the other day, and decided to finally burn in the exhaust. I welded the muffler all the way around, then made a hangar bracket to use the original exhaust mount on the frame.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0159.jpg)
When I finished that I started pondering how I was gonna fab up a rear torque arm, and my eyes fell on the brake pedal that came with the YZ rear brake setup.... If I can't use this, it'll at least make a good pattern. I love the curvature, and it goes around the shock perfectly, minus the little spring tab.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0160.jpg)
It looks like it's really close to the tire, but I've got 3/4" clearance easy. I suppose I should've gotten a better shot to that effect.....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 26, 2013, 16:51:32
I haven't abandoned this project, but I had a few obstacles keep me from doing anything meaningful. Biggest would be.... It's FUCKING COLD!! lol. No worries.... New developments to come!
Title: Re: Project Shinjimei- 73 TX500
Post by: MotorbikeBruno on Dec 29, 2013, 09:25:39
I hear ya on the cold.  I'm willing to be patient..I dig this build  8)  Look forward to more when it's not insanely cold out! 
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 14, 2014, 03:36:00
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0008.jpg)
Holy shit! I did something!
Got some headlight ears off eBay....
 (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0010.jpg)
I really like how the LED headlight looks with the inverted front end...
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0009.jpg)
Unfortunately my bar-end signals don't fit the aluminum bars so well.... I'll either have to turn down the body on the signals or ream out the bars.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Feb 14, 2014, 11:29:15
Great to see you still on this man the headlight looks the part !
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Feb 14, 2014, 15:53:05
Looks rad now get it done my man
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 14, 2014, 21:32:55
Oh yeah.... Cold or not, I got work to do... Anyone know what size socket I need for the sprocket nut, BTW?
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Feb 15, 2014, 09:53:37
For some reason 25 or 27 mm is coming to mind but not 100% on it
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 15, 2014, 11:06:43
Huh. I could have sworn I tried a 27 and it was too small.... Guess I'll try again! I suppose I've always got my vernier caliper if I need to measure it... Oh well. Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 16, 2014, 09:39:56
32mm..... That's a big sucker.....
Title: Re: Project Shinjimei- 73 TX500
Post by: MotorbikeBruno on Feb 16, 2014, 16:23:37
32mm..... That's a big sucker.....

If you don't have them already, you will be happy when you do.  I got all those odd large sizes a while back, it's worth it when you realize you are 1 or 2mm shy of having the correct one, and that huge adjustable wrench doesn't cut it.  Love the progress so far!
Title: Re: Project Shinjimei- 73 TX500
Post by: rundown on Feb 16, 2014, 22:43:33
This is very interesting, especially to me as I am building an XS500, or at lest I have one that is apart and sitting in my garage.  Watching this and really liking what you have done so far.  I did not see mention of what rear sets you used?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 17, 2014, 00:04:57
The rearsets were on page 3. I took them off an 87 Hurricane 600. I needed to move the sidestand forward 3 inches to use them, cuz my toe wouldn't clear, and I did have to weld some brackets into the "v" of the frame.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 21, 2014, 10:31:42
Well, I finally ordered the last bits that I don't have to make or modify: the chain and left handlebar switchgear. I originally planned to use toggle switches for high beam and turn signal functions, and I do have them if I still go that way, but my plan to use a squeeze-bulb horn was stupid. Electric horn with a button it is. I have quite a bit of work to do with wiring, and nailing down my system for anchoring the brake calipers (plus odds and ends like making front fender mounts, and getting the bar-end signals to fit IN the bars...) But things are progressing. I'm really hoping to have her rideable by June, because Rockerbox is now being held at the same time and place as the AHRMA races I always go to, not the usual August date.....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 07, 2014, 16:33:20
I've been dragging my feet a little due to the cold, but I had to do something. What I'm left with is this:(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG003_edit_1394224806452.jpg)
In my haste to get the new wheels on, I apparently forgot how difficult it is to swap sprockets without a chain around the old one. You know, to keep it from spinning when you try to loosen the nut. So I figured: why not weld a piece of steel to the sprocket for the same result? Attempt one did not work. The piece of steel isn't thick enough, and my cheap_ass Harbor Freight welder can't penetrate the sprocket. On to attempt number two!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Mar 07, 2014, 18:17:34
If you have the old chain just wrap it around the front and back . Take safety wire to close the loop and see if that works ?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 07, 2014, 18:25:42
The old chain is long gone.... I tried the new one, but it's a 520 so it won't grab. I'm thinking I might have a chain wrench somewhere, though....
Title: Re: Project Shinjimei- 73 TX500
Post by: xb33bsa on Mar 07, 2014, 19:24:52
good looking project
the rear brake arm is under some pretty extreme compression mounted topside like that, it needs to be stout and straight, that brake pedal won't do,too flexy, used as shown it will crash you when it folds up under some brake chatter and the wheel locks or worse
 why not hang the caliper down and use a torque arm under tension ?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 07, 2014, 19:58:27
The caliper I have is from the same bike as the hub- it was meant to be mounted on top. I had my concerns about the brake pedal torque arm flexing, I'll admit, but I figured: it's strong enough to hold my weight, and I never use the rear brake.  Mainly, the brake pedal is only a template for something stronger. I need the curvature to clear the shock. I suppose I could run a mono-shock and use the torque arm from the Ninja 250 I got the swingarm off of....
Or, I could focus on the front brake, which I actually use.
Title: Re: Project Shinjimei- 73 TX500
Post by: xb33bsa on Mar 07, 2014, 20:05:21
The caliper I have is from the same bike as the hub- it was meant to be mounted on top. I had my concerns about the brake pedal torque arm flexing, I'll admit, but I figured: it's strong enough to hold my weight, and I never use the rear brake.  Mainly, the brake pedal is only a template for something stronger. I need the curvature to clear the shock. I suppose I could run a mono-shock and use the torque arm from the Ninja 250 I got the swingarm off of....
Or, I could focus on the front brake, which I actually use.
as a template will be fine , don't underestimate the usefullness of the rear brake
if you are riding on the street you should to learn how to use both brakes
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 07, 2014, 20:10:44
Lol. I'm aware of the usefulness of the rear brake, especially in loading the front suspension before a turn, I just have never had a bike that had a rear brake worth using. Looking at how tiny this thing is, I don't figure this one will be any different. Mostly , I'm just a stubborn asshole and don't take constructive criticism well . Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: xb33bsa on Mar 07, 2014, 20:24:13
there nice if you have t layer down ;D
when into harder braking,while turning,i like to use pretty heavy rear brake along with the front brake on my street rides, if i leave a little reserve with the front, i find it can come in handy for those suprises that pop upon the street,if that makes any sense  :-\
in other words if i need to really cramp on the front maybe even stand it up a little having the rear already under braking seems to keep things inline better
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 18, 2014, 21:07:36
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0037.jpg)
I finally took the time to run up to Harbor Freight and grab a cheapie electric impact gun, and spun the front sprocket off... The new one doesn't look too different, other than obviously being thinner to fit the 520 chain as opposed to the original 530. But when laid on top of each other.....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0038.jpg)
You see the new sprocket is 2 teeth or so bigger than what was on the bike. Guess the original owner wanted some more zip, because I'm running the original 17/43 gearing.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0040-1.jpg)
Of course, the point of this exercise is this: new sprocket and chain installed. I'm functioning brakes and wiring away from a complete motorcycle. Er.... Well.... One I can ride anyway...
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Mar 18, 2014, 23:26:26
Time to buy more Alcohol and happy pills ... It almost tuning time  ;D
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 18, 2014, 23:54:57
Scott, my thoughts exactly. Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: bradj on Mar 19, 2014, 09:27:09
Just checking it. keep fighting the good fight my man
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Mar 29, 2014, 01:10:51
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG004_edit_1396066699027.jpg)
Minimal progress. The weather has still been too cold to be outside for more than a few minutes at a time. I got a start on my aluminum chain guard, and I started hacking up the original wiring harness so I can keep the charging system, but eliminate everything else. Until next time....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 05, 2014, 02:59:07
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMG_53387455092198.jpeg)
Ah, wiring... Bane of my existence....
Title: Re: Project Shinjimei- 73 TX500
Post by: SrgtBear on Apr 05, 2014, 17:01:57
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMG_53387455092198.jpeg)
Ah, wiring... Bane of my existence....

Looks like "tumble-weave."
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 06, 2014, 12:03:14
Lol. It ain't pretty. But I gotta deal with it. I have the starting circuit finished, the lighting I'm doing from scratch, and the ignition stands alone, so all I need from the original harness is the charging system. Should look much better once I strip away all the other crap.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 22, 2014, 22:54:15
Finally- FINALLY- got the harness stripped down to just the charging system.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG005_edit_1398218296545.jpg)
Found a few discarded plugs I can re-purpose, too.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0049_1.jpg)
I even managed to burn in the final iteration of my seat mounts. Thumb screws!
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0054_1.jpg)
I think it'll be great to be able to pop my seat off without the use of tools....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 25, 2014, 10:02:41
I realized I never did specify where I mounted my starter solenoid....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG006_edit_1398430663086.jpg)
Strangely, not far from its original location.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG005_edit_1398431036728.jpg) I happened across this guy last time I was at the boneyard, too. Relevance? I read an article on the TX/XS500 forum detailing how to replace the original split regulator and rectifier with this unit. Since the original Yamaha bits are not known to fail, I hadn't actually planned to do it, but....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG005_edit_1398431109955.jpg) When I took a closer look at the rectifier, I found this. Not only is the plug melted together, but the outer layer of insulation is burnt. Not to mention the wires underneath. Plus:
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG005_edit_1398431607087.jpg)
Being an aftermarket bit, it's actually an improvement over the original, and they were even nice enough to spell out what wires go where, right on the unit. Classy!
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG005_edit_1398431860644.jpg)
Finally, everything mounted on its final, permanent location. I re-organized it a bit to make more room, but hell, it's still pretty compact. I like it!
Title: Re: Project Shinjimei- 73 TX500
Post by: SrgtBear on Apr 25, 2014, 10:41:37
I want to see a video when you got that electronic timing figured out.  Need to see if that something I should invest in.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 25, 2014, 11:13:02
It's actually really simple to hook up, but I've heard some bad things. There is a guy up in Appleton runs his own business called C5, making his own optical electronic ignitions. All kind of bikes. He also runs the Kneeslider website- Paul Crowe is his name. ( I may have the specifics wrong, but if he isn't the same guy running the business, they're at least buddies.) I'm going to give the Newtronic a shot, because it was expensive, but if it fails, I'm going local....
Title: Re: Project Shinjimei- 73 TX500
Post by: Maritime on Apr 25, 2014, 11:18:09
Ask Dreadrock about the TX500 ign by Newtronics, I believe he is back to points after sending his back 3-4 times to them. Pretty cool Paul from the kneeslider builds ignitions. I read his blog everyday, love it.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Apr 25, 2014, 13:15:46
Yep it's a pricey part and slide right in BUT points ended up working way better just ask the 4 or 5 guys that helped work on it durning mid-Ohio LOL had us all drinking more LOL I do hope it works out for you tho bud just remember if you do go to points you need to add 2 condensers ! Let us know how it goes
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Apr 28, 2014, 13:49:48
my bikes all have points  ;) 
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 28, 2014, 18:25:30
Y'know, Dean, this is the first motorcycle I've even considered running points. I hate them .  HATE. But since I did find an electronic ignition, I hope it works. If not....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 01, 2014, 10:22:33
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0066.jpg)
My guy at work finished reaming out the ends of my bars to fit the bar-end signals, so I got cracking. Realizing the signals would end up sealing the lowest point of the bar- so any water that got in wouldn't get out- I figured it'd be prudent to stop water from getting in.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0065__edit_1398949910765.jpg)
Here is a demo of fitment. I think they look pretty inconspicuous....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0067_1.jpg)
And here I ran some power to check light output. Not so inconspicuous  any more !
Title: Re: Project Shinjimei- 73 TX500
Post by: SrgtBear on May 01, 2014, 11:11:34
Neat!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 02, 2014, 22:53:29
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0070_1.jpg)
First signs of life!
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on May 03, 2014, 11:56:42
Awesome ! I would really like to see it work flawlessly for you  :)
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on May 03, 2014, 12:40:57
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0070_1.jpg)
First signs of life!

Why is it when I saw this pic all I could think about is " Evil Evil eyes Laughing at me from afar " LOL

I'm with dean tho I really hope its work flawless for you !

Make It Happen Captain !
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 09, 2014, 19:15:42
So..... I guess it's a pretty common problem, but I'm not sure how to deal with it. A piece of the little tab that holds the clutch cable broke off the cases.... Any advice?
Title: Re: Project Shinjimei- 73 TX500
Post by: xb33bsa on Jun 09, 2014, 21:04:26
post up a picture
i have seen and done myself a repair with a bolt on piece not for a tx but
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 19, 2014, 08:05:28
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG016_edit_1403175712500.jpg)
Yes, it's a crappy pic, and my finger is in the shot, but this is how the tab that holds the clutch cable is supposed to look.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG017_edit_1403175470308.jpg)
This, however, is what I'm left with.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jun 19, 2014, 15:54:22
Trying to remember if that is part of the cover or part of the lower case ?
Title: Re: Project Shinjimei- 73 TX500
Post by: xb33bsa on Jun 19, 2014, 16:20:29
it has to be part of the maincase i have a stator case here and it has no cable housing stay
i would just fab up a simple bracket there is plenty of threaded holes to attach to
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 20, 2014, 22:58:35
I actually came up with a solution at work yesterday! My inspiration was a stripped-out nut, believe it or not. The piece that's left still holds the cable fine until I put the cover on. It seems the side load forces it off the holder. So, all I had to do was cut a channel in a nut to slide over the remaining piece. Keeps the cable from sliding off sideways. BOOM.
Oh. Yeah. It's part of the main lower case. If I couldn't come up with a solution I'd be looking for a new motor.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Jun 20, 2014, 23:48:26
Good deal man congrats !



Or some that has a parts motor sitting around  ;)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 10, 2014, 18:59:56
 http://s961.photobucket.com/user/BurnOutSX4/media/XS500%20project/VIDEO0015.mp4.html  (http://s961.photobucket.com/user/BurnOutSX4/media/XS500%20project/VIDEO0015.mp4.html)
Could I be the only guy so far to purchase an electronic ignition for a TX500 and have it work? Kinda looks that way!
For the record, I have absolutely no idea how to post a video. It's a link to my video on photobucket.com.
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Jul 10, 2014, 23:33:18
fixed it>?  ;D


(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/th_VIDEO0015.mp4) (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/VIDEO0015.mp4)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 11, 2014, 06:38:44
 Well, DeanJ, it didn't work on my end.... But if it works for everyone else, I'll call it a win. The point is, the bike runs. It needs tuning- badly- but it runs!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 29, 2014, 00:10:08
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0186.jpg)
My final solution for a torque arm for the rear caliper. Now to find a better photographer....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 01, 2014, 22:18:15
I took the week off to try and finish the bike for my birthday (yesterday), and I almost succeeded. Other than the turn signals and speedo, the wiring is done. Everything works... But I screwed up making the throttle cables and I have to start over. More updates to follow.
Title: Re: Project Shinjimei- 73 TX500
Post by: rundown on Aug 03, 2014, 21:43:43
This has been a long hard road, it looks like you are about ready to reap your rewards.  Congratulations on a nice bike.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 04, 2014, 13:08:30
Rundown, that is no joke. Can't describe how anxious I am to put some miles on this thing!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 05, 2014, 22:54:40
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0025__edit_1407290174997.jpg)
The LED headlight is bright as hell. More so than I even expected.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0026__edit_1407290205986.jpg)
The gauge is cool, but I need to wire the power to a direct line. The illumination kills every time I turn on the high beam. Also, I need to move it back up in front of the top tree. You really have to be looking at it from a certain angle to read it, and on the headlight isn't it.
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG002_edit_1407290225274.jpg)
The extra-loud low-tone horn is kind of a joke.... But it works a treat!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 07, 2014, 22:42:36
Alright! I got impatient, so I took the dirty bitch for a quick blast up and down the alley..... Shinjimei's First ride!: http://youtu.be/Y3GaQrN8tvE
Gotta say, I'm a little freaked out. The charging system doesn't appear to be working.... The brakes suck, and the motor, while really powerful, is really noisy. Like, possible rod-knock noisy.... Didn't get too up close and personal, so I'm hoping it's a loose head-pipe on  the exhaust, but damn.... It sure would suck if this motor is cooked after all this work....
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Aug 08, 2014, 10:30:18
I feel your pain man !! Keep at it you'll get it I'm sure
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 10, 2014, 09:23:17
Yup. Charging system was an easy fix- had the wrong wire connected to the regulator to energize the field . Brakes just needed bedding in. Unfortunately, the motor does indeed have a rod knock, and it's completely my own fault. I had intended to change the oil, before any sort of use, and forgot. The oil was really gassed out, and I'm pretty sure that wrecked the rod bearings . It sucks worse, because this motor goes like a raped ape. Seriously. Strongest 500 I've ever ridden .  Oh well. Guess I'll look for parts to do a bottom- end rebuild.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Aug 23, 2014, 22:22:04
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0043__edit_1408843085545.jpg)
This is my best friend Jake with my bike. You'll notice that it's not in my garage! I decided to take her to bike night at the Quaker Steak and Lube. Unfortunately, that's as far as it went. Whence, the thumbs down. Seems riding a bike with a rod knock is a bad idea.....
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0044__edit_1408843140318.jpg)
Soooooo.... I had to get her trailered home to get ready for a motor swap. You can see I'm thrilled. Lol.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 23, 2014, 20:58:15
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/DSCN9364__edit_1410668105577.jpg)
Thanks to deanj, the resurrection begins! I bought this lovely '78 bottom end to replace my fragged '73. Can't wait to hear it  again!
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 23, 2014, 21:06:48
 Did you get the charging system working ? Could there be air still in the brake lines ?

 
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 23, 2014, 21:13:17
Oh, yeah, I thought you saw my earlier post! I just had the wrong wire connected to energize the field coil, so yeah, the charging system works, and the brakes apparently just needed bedding in.
Title: Re: Project Shinjimei- 73 TX500
Post by: DreadRock on Sep 23, 2014, 21:34:55
 Missed that LOL
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 23, 2014, 21:43:00
Hey, it's a big forum. Can't catch everything. Lol
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on Sep 25, 2014, 09:36:14
Looking forward to hearing her run again !  I was great to meet you and the big man Jake ( I have never seen anyone palm a 500cc engine with one hand before  ;D)
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Sep 25, 2014, 10:36:56
Lol thanks Dean! Was great meeting you, too. Yeah, Jake is a good friend to have around when you need something heavy lifted.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 12, 2015, 01:00:36
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0149.jpg) First picture worth posting in quite a while.... But I got a couple hours out in the garage tonight, and this was the result. I might even have her running again before Rockerbox!
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2015, 14:28:41
(http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/IMAG0164_1.jpg)

You ever have one of those moments when you said, "Shit, I wish I hadn't done that..."?
Yep. This is one of those moments. How much you wanna bet I have 4 bent exhaust valves?

Seems running a late head on an early motor has some issues....
Title: Re: Project Shinjimei- 73 TX500
Post by: SrgtBear on May 25, 2015, 17:11:42
Yikes!  Sorry for your loss on this one. I guess someone had to try what you did eventually. Just sucks you were the guinea pig.

Id probably search for a new motor at this point. Finding replacement parts will be a bitch.  Especially if your cylinder wall is scored from the particles, then you will need a fresh hone and new rings. Not to mention those Pistons are now done. It will probably cost you more vs getting a donor engine.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 25, 2015, 18:16:07
The funny thing is, I got a 78 bottom end from Dean j already (i really thought the whole issue was a rod knock, which may still be the case),so the bottom end is taken care of.... The issue is, now I need another replacement head. Or at least 4 exhaust valves and a skim.
As an aside, the reason this happened was at least partially my own damn fault. I'll explain later....
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 29, 2015, 19:56:12
So, the reason the exhaust valves contacted the pistons was at least partially my fault. I had issues timing the exhaust cam. No matter what I did, the timing marks wouldn't line up. Either the mark on the cam was on one side of the pointer or the other. I picked one, buttoned it up  and never bothered checking if there was an issue. Mostly because I only had one had gasket and couldn't afford another one at that time. So.... I'm thinking I picked the wrong side of the pointer. Better luck next time?
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on May 30, 2015, 19:45:39
 :o ouch!

Although the casting process improved for the one piece head and improvements were made over the years ,such as the round port E exhaust , the actual cams and valves are the same parts on all of the TX/XS500's heads '73-'78. The the higher comp 2F1 pistons in that E motor are also a common upgrade when rebuilding the older 371 engines.
 
With the timing pointer at the "V" on the plate and all of the cam chain slack to the exhaust side with full pressure on the tensioner, the dots on the cams "pretty much" align with the arrows on the caps. "pretty much" means they are not precisely aligned, however if they are off a tooth either way, it is absolutely positively obvious it is incorrect.

Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 30, 2015, 19:47:55
Yeah, I had it on the exhaust side of the mark, so I thought for sure it was right.... Guess that wasn't the case this time.
Either that, or trying to put a 76 head on the 73 bottom end isn't the hot ticket.
Just to clarify, it's taken me this long to remove the head from my old motor- this isn't the 78 bottom end I got from you, Dean. That's still waiting to go in.
Title: Re: Project Shinjimei- 73 TX500
Post by: DeanJ on May 30, 2015, 19:59:13
I'm far less freaked out then  :P
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 30, 2015, 20:12:25
Lol yeah, I probably should have mentioned that.... I do know that the 73 motor was the only year that had compression as high as the 78s.... And I had some interesting issues with fitment. If, as you say, the slack should be towards the exhaust side, I had had it right after all... So maybe it's an issue with deck height...
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jun 15, 2015, 00:00:47
Some closer inspection has revealed what caused this debacle..... I mentioned someone had been inside this motor before, right? Seems they knew to fit the'78 pistons. The bike had 1mm over '78 pistons fitted already. The addition of the late model head to that is what caused the valve-to-piston contact. The valves are indeed bent. Even worse, it looks like the exhaust cam journals are worn out from the extra pressure, as well.

Anyone looking to part with a Suzuki GS500e motor, cheap?
Title: Re: Project Shinjimei- 73 TX500
Post by: Jewbacca on Dec 20, 2015, 03:34:20
I really hope this project isn't stalled permanently. I'm in the process of tearing my 74 TX apart and I'm noticing the same issues with mine as yours, so I know what to look for now! LOL. But seriously, did you ever finish her up?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 20, 2015, 11:13:28
No.... Unfortunately I haven't had a lot of free time since my son was born. Lol. I'm actually considering going to a different engine, even though I bought this beautiful '78 bottom end. I wrecked the '76 head, and I'm not sure if it's worth buying another one. Tri-maha maybe? 😉
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 27, 2016, 10:25:33
I've decided to sell my Hyosung GT250R to finance the completion of this project. If anyone has an old two-stroke single over 350cc, or a complete but wrecked parallel twin over 450cc, I'd do trades, but I'm not holding my breath.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Dec 09, 2016, 15:19:52
Well.... There hasn't been any progress in a while. The bike has been sitting in pieces in my grandma's garage following the breakup between my son's mother and I. With no time or money, or even a place to work, it's been put on the back burner.
That being said, I've got a line on something really unusual for tax time... A guy at work has a couple APU's sitting in his yard, with good engines. (In case you didn't know, APU stands for "auxiliary power unit". They're basically little diesel generators that also run the heat and AC on semis when they're parked up. Saves fuel and wear and tear. Since they don't have to have the main engine idling the whole time.)
The engines in question are 570cc liquid-cooled diesel parallel twins. I'm told they're rated at 28hp. Or the same as my Hyosung 250cc.
But that's without adding a turbo. Sounds like I might be doing something a little unorthodox....

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Title: Re: Project Shinjimei- 73 TX500
Post by: Jewbacca on Dec 10, 2016, 19:35:50
I am on board to see this bastard child come alive.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 03, 2017, 00:26:04
http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/4725_1.jpg (http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/4725_1.jpg)(http://http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/4725_1.jpg)
Alright, here's a picture of an engine like the one I've procured. It's a 2TNV70 Yanmar, for those that are interested in the specifics. I chose this shot to showcase how narrow the motor actually is. Specs say 18 inches wide, 21 inches high, 16.9 inches from front to back. It should fit fairly snug in the TX frame. The reason things are taking me a awhile is I'm trying to figure out what sort of transmission I'm going to be able to use behind it. My first thought was to try and use an aftermarket Harley trans, like a Revtech 6 speed, but I hate Harley's enough (and the prices associated with them) to find that idea distasteful. Perhaps a Norton Commando unit, or something like it.

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jul 03, 2017, 00:29:26
http://i961.photobucket.com/albums/ae98/BurnOutSX4/XS500%20project/download.jpg
Specs on the engine size.

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Title: Re: Project Shinjimei- 73 TX500
Post by: stroker crazy on Jul 03, 2017, 01:06:01
I've seen a couple of attempts to do a diesel conversion; usually lots of torque but not very responsive.

Good luck with it if you go ahead!

Crazy
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Jan 31, 2018, 23:21:12
Well,  looks like the diesel idea isn't going to work...  I found an Enfield 5 speed trans,  and worked out the dimensions,  but the cost if the tranny and the machine work to mate it to the engine just wasn't worth it....  So I bought a non-titled Honda Rebel 450 for 600 bucks.  I'm working on getting some Chinese-made Keihin-clone flatslides to fit the Honda motor,  and then it's getting shoehorned into the TX chassis.  Most likely with the Honda lower frame cradle.  We'll see.  Onward and upwards!

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 15, 2018, 22:43:02
It's funny the little things that can hold you up and get on your nerves....  The Honda Rebel 450 came with a 525 pitch chain and sprockets,  and my Yamaha came original with 530 pitch,  which I converted to 520, to match the YZ250 rear hub I used.  Now,  I can't for the life of me get the two to match. I can't find either a 520 front sprocket for the Honda motor,  or a 525 sprocket to fit the YZ250 rear hub..... I might resort to welding my Yamaha front sprocket's teeth onto the Honda sprocket....  But I hope I don't have to resort to that.
Title: Re: Project Shinjimei- 73 TX500
Post by: Pete12 on Feb 16, 2018, 06:34:32
I can't find either a 520 front sprocket for the Honda motor,  or a 525 sprocket to fit the YZ250 rear hub

Has the Rebel got a fine or coarse countershaft spline (13 or 6)? You might find a sprocket from an XL500/XR600 that will do the job. Most sprocket sellers on Ebay include a dimensional drawing that makes it really easy to mix and match.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 16, 2018, 22:50:58
I have no clue.  I haven't taken it off the bike.

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 16, 2018, 22:52:06
Thought I'd try and post a pic of the donor bike...   https://i.imgur.com/d2fUj83.jpg

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Title: Re: Project Shinjimei- 73 TX500
Post by: furu14 on Feb 17, 2018, 11:16:22
you coud grind down the 525 sprocket to 520? or use a lathe?
520 is just a tad narrower?
Title: Re: Project Shinjimei- 73 TX500
Post by: Jewbacca on Feb 17, 2018, 16:27:59
Maybe buy a blank sprocket from somewhere like McMaster-Carr and have it broached at a shop to fit the splines of the engine?
Title: Re: Project Shinjimei- 73 TX500
Post by: Pete12 on Feb 17, 2018, 23:35:15
I have no clue.  I haven't taken it off the bike.

I can understand your trepidation, it's a major job, not to be undertaken without considerable forethought and planning, not to mention the special tools involved 😃😃
Title: Re: Project Shinjimei- 73 TX500
Post by: ex119x on Feb 17, 2018, 23:51:51
The sprocket from a 79 - 81 Honda XL500S has the same spline as the CMX450C. It is a 520.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 18, 2018, 11:41:34
I can understand your trepidation, it's a major job, not to be undertaken without considerable forethought and planning, not to mention the special tools involved 😃😃

Oh,  you're funny.  Lol.
Seriously,  though,  I haven't had the time or desire to freeze my ass off out in the garage. When it's above 20 degrees Fahrenheit for more than a day,  I'll be moving fast on this. 

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 18, 2018, 11:42:21
The sprocket from a 79 - 81 Honda XL500S has the same spline as the CMX450C. It is a 520.
Thank you! That's exactly the information I needed.

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 18, 2018, 11:43:41
you coud grind down the 525 sprocket to 520? or use a lathe?
520 is just a tad narrower?
No,  520 is a narrower 530. 525 had different distance between the rollers.  Tooth pitch,  if you will.

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 18, 2018, 11:44:52
https://i.imgur.com/fU5Fj43.jpg
I did finally get these bad boys.   

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Title: Re: Project Shinjimei- 73 TX500
Post by: Pete12 on Feb 18, 2018, 18:54:28
No,  520 is a narrower 530. 525 had different distance between the rollers.  Tooth pitch,  if you will.

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520 is 5/8" pitch x 1/4" width, 525 is 5/8"x5/16" and 530 is 5/8"x3/8", all the same pitch.

Love the new carbs, are they the Chinese copies and, if so, what's the quality like?
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 18, 2018, 19:47:46
520 is 5/8" pitch x 1/4" width, 525 is 5/8"x5/16" and 530 is 5/8"x3/8", all the same pitch.

Love the new carbs, are they the Chinese copies and, if so, what's the quality like?
I stand corrected...  I knew that you could use 530 chain on 520 sprocket in a pinch...  Didn't know 525 has the same pitch.  Might've saved myself some aggravation if I hadn't already bought a new sprocket. 
They actually look every bit as good as real Keihins,  to be honest...  Maybe the finish is a little more dull,  but they did a really good job machining the bores and slides. I'm surprised.  And at the price,  I don't care if they fail.  I can still afford Mikunis if they do.

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Title: Re: Project Shinjimei- 73 TX500
Post by: Pete12 on Feb 18, 2018, 23:48:56
Good stuff. The only thing I would do with carbies is put genuine Keihin jets in, particularly the mains, as the Chinese jet sizing sometimes leaves a little to be desired. I've seen a larger jet number with a smaller hole which obviously causes all sorts of problems.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 19, 2018, 23:10:27
Good stuff. The only thing I would do with carbies is put genuine Keihin jets in, particularly the mains, as the Chinese jet sizing sometimes leaves a little to be desired. I've seen a larger jet number with a smaller hole which obviously causes all sorts of problems.
Indeed. I know I'm gonna have to change the jets anyway. Might as well get the good stuff.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Apr 27, 2018, 19:41:03
http://imgur.com/gallery/VZDsZ65
I made my first attempt at fitting the Rebel 450 engine into the Yamaha frame.  After I cut off all the original Yamaha mounts,  it'll go right in.  Then I need to fab up new mounts. 

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 10, 2018, 20:22:44
I decided to replace the lower frame section of the Yamaha with the part of the Honda frame that holds the motor mounts.  I figure it's easier than trying to make room in the Yamaha frame as it sits, plus it allows me a little room to place the motor where I want it.
Anyone need some Rebel parts?

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Title: Re: Project Shinjimei- 73 TX500
Post by: datadavid on May 11, 2018, 04:18:03
Props for building anything with yamahas worst, most fragile and unreliable bike ever
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 15, 2018, 21:42:15
Props for building anything with yamahas worst, most fragile and unreliable bike ever
You know, it's not as bad as people think.  Especially the later models.  By '78, they really had it nailed. I mean,  think about it. You had a DOHC, 4 valve-per cylinder design with a balance shaft,  and by then they had everything set up to be either self-adjusting,  or extremely easy to do.  And they had higher horsepower then any other 500 twin for years.  Even the Ninja 500 didn't make as much power. Yeah, they had quirks, but when did any design not start out with some issues? Yamaha fixed everything,  then gave up.

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Title: Re: Project Shinjimei- 73 TX500
Post by: datadavid on May 16, 2018, 05:04:29
Cool, they have a horrible reputation here, tx750's being the worst. Apparently all balancer and oil froth issues can be solved though.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 17, 2018, 17:34:17
Cool, they have a horrible reputation here, tx750's being the worst. Apparently all balancer and oil froth issues can be solved though.
Yeah,  it's the TX handle that gives everyone fits,  and it's all because of the 750. The 500 had the balance shady up high,  above the transmission.  Only real issue was that it was difficult to adjust the tension on the chain driving the balance shaft on the early models,  and of course there was the cylinder head cracking issue on those as well.  '76 and later were really nice.

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 17, 2018, 17:35:19
Well..... No going back now...

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Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on May 18, 2018, 22:35:36
Yeah,  it's the TX handle that gives everyone fits,  and it's all because of the 750. The 500 had the balance shady up high,  above the transmission.  Only real issue was that it was difficult to adjust the tension on the chain driving the balance shaft on the early models,  and of course there was the cylinder head cracking issue on those as well.  '76 and later were really nice.

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Shaft. Balance shaft.
Title: Re: Project Shinjimei- 73 TX500
Post by: two-smoker on Feb 11, 2019, 22:47:06
I ain't dead yet, bitches! Just poor.......(http://http://imgur.com/gallery/Gd834yp)

http://imgur.com/gallery/Gd834yp(http://http://imgur.com/gallery/Gd834yp)
Title: Re: Project Shinjimei- 73 TX500
Post by: 1fasgsxr on Feb 12, 2019, 13:32:10
I sure know that poor feeling!