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Blood Sweat Tears and Grease => Projects => Enduro / Dirt / Scramblers => Topic started by: MCKAY34 on Apr 08, 2017, 22:23:05

Title: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:23:05
Hello everyone,
Starting a new build, picked this bike up last week. Its a 1980 xt500, however it doesnt have a matching engine. Im still trying to figure out what year the engine is. 1E6-302000 if anyone knows please let me know.

Plans for the bike.
- strip down, repaint and rebuild.
- 12v conversion
- virtually rebuild the entire bike, its pretty rough.
- I am going to use the bike for an extra run around bike and some off road trails.

The bike is pretty stuffed. it doesnt run or ride and my mechanical experience level is not great, so any help would be greatly appreciated
So lets get started!
WISH ME LUCK!!!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:30:49
Cleared some space in the garage, so i have a nice clean area to work. and can start the strip down.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:37:55
Started pulling it apart, the more i dive into this bike the more parts i relise i need to order.
no problems, so far. A few tough bolts here and there, but pretty easy so far.

also got the engine out !
its on my bench so i can work on it better, its the first thing im going to try and rebuild.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:48:30
I was cleaning the oil pan/bowel thing and amongst all the crap. i found this chunk of metal. It scared the hell out of me. but after some research and diving into the motor a bit more i discovered the metal was the kick starter stop block. Apparently this happens a lot.
Anyway, i can add that to the parts list.
its pretty easy to replace, just 3 bolts. Further inspection, it doesnt seem to have done any damage.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:53:41
i pulled the carb apart , i will do a full rebuild of this. and im hoping to get it hydro blasted. along with some other parts, so super excited to see how that turns out.

The carb looks to be in pretty good condition.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:55:40
here is the kick starter piece that broke.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 22:57:43
here is the kick starter piece that broke
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 23:04:42
ok at first glance does anyone have any thoughts on how this looks?
valves and piston.
 i will be replacing the valves as soon as i can find out what year my engine is.
also one of the springs have snapped on the valves so i will replace all of that also.

any thoughts on the colour of this piston and valves, seems to be very black.

i cleaned the piston very easily, and looks ok
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 08, 2017, 23:13:49
Does anyone know what year my engine is?
xt500 number: 1E6 - 302000
Title: Re: 1980 XT500 BUILD
Post by: bingowings on Apr 09, 2017, 04:28:49
1976 :)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 09, 2017, 04:31:20
hey thanks for the reply.
how do you know its 1976?

i thought 76 didnt have the compression window. but this one has it
Title: Re: 1980 XT500 BUILD
Post by: cxman on Apr 09, 2017, 10:09:59
in the picture mind you my eyes are getting old

the spark plug threads look awful pls check and make sure its my eyes and not that you need a helicoil
Title: Re: 1980 XT500 BUILD
Post by: lennong on Apr 09, 2017, 10:41:56
Does anyone know what year my engine is?
xt500 number: 1E6 - 302000
According to this, looks like 1978..
http://xt500.free.fr/technique/numero.html
(https://uploads.tapatalk-cdn.com/20170409/10b7060fa6731972d7776cc016e22851.jpg)

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 09, 2017, 18:05:23
The spark plug thread is all good!

Checking that list, why would you say it's a 79?
Because the 1e6 number is also next to the 76 model?


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Title: Re: 1980 XT500 BUILD
Post by: lennong on Apr 09, 2017, 18:28:30
1E6-300101-310000 2H2XT 500 E 78... If your vin is 1e6 302000 thst falls in between those #s doesn't it? So 1978.. That's just how I'm reading it maybe?

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 09, 2017, 18:52:42
Ok thanks for your help.


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Title: Re: 1980 XT500 BUILD
Post by: hillsy on Apr 10, 2017, 06:42:45
Your tank is 1980 colour scheme. You might have a 1980 chassis with a 1978 motor.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 10, 2017, 07:09:58
yep! thanks exactly what i have.
yamaha finally called me back. its a 78 engine. and my frame is an 80.

thanks to everyone! problem solved, time to keep kicking on with the build.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:03:48
havnt posted in a while,
i have been waiting for parts to arrive, just been tearing more bits apart. did some painting while i have been waiting for parts to arrive.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:06:29
did some painting while i have been waiting for parts.
going with satin black for the engine.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:11:49
I feel the frame is too long. i have taken 9.5cm out of the rear loop. Only for aesthetic reasons, the seat i want to make will be a little bit smaller.
I have welded it back together and it looks pretty good and worked great.

im going to try and fit a TT500 rear fender. the original wont work now, because i have changed the rear loop.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:17:08
I welded some tabs for the rear TT fender. works pretty good,
i think it looks ok.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:20:13
Just mocking up a battery and wiring box. welded some tabs for the box.
i know it looks rough, but its just a mock up.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:23:03
Some parts have arrived so i rebuild the carb.

Check out the hydro blasting job on the carby. ohhhhhh wow! i love hydro blasting. looks sick.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 24, 2017, 05:27:37
New parts arrived so i fix the kick start stopping plate.
feels good when you find a problem, and get it fixed.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 29, 2017, 21:34:27
Hi guys, frame is painted and looks great. just getting some cleaning of old parts done, while i wait for new parts to arrive.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 29, 2017, 21:37:57
Always the best way to remove old spokes, i started taking them off , but they were a little rusty and doing my head in, so the grinder jumped off the wall and was begging me to use it.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 29, 2017, 21:47:22
Just wondering if anyone knows if there is a torque setting for this nut?
Its the nut that holds on the contact breaker drive pinion

Any help would be much appreciated.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 03, 2017, 06:54:49
stripped the tank today, need to repaint, ill probably go with a yamaha yellow and gloss black tank, im not sure yet.
Title: Re: 1980 XT500 BUILD
Post by: interceptor on May 05, 2017, 18:16:06
Cool project you got going.  BTW, I like the tank bare  ::)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 05, 2017, 18:30:44
Cool project you got going.  BTW, I like the tank bare  ::)
Thanks mate! Yeah the bare tank does look awesome. But it has a few too many scratches and dings. Unfortunately painting might be the best option.
Title: Re: 1980 XT500 BUILD
Post by: Martin M on May 07, 2017, 03:30:12
Just wondering if anyone knows if there is a torque setting for this nut?
Its the nut that holds on the contact breaker drive pinion

Any help would be much appreciated.
This nut needs 60 Nm, and use Loctite medium (243), or somthing similar.

Martin
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 07, 2017, 06:07:27
This nut needs 60 Nm, and use Loctite medium (243), or somthing similar.

Martin
Awesome Martin thanks for the reply and information, I will do exactly that. I appreciate the advice. Going to start the rebuild this week
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 10, 2017, 05:15:47
Hello all, thanks everyone for all the feedback so far.
i have just noticed a little issue with the valve guides. i am just about to start rebuilding the bike, so the fun stuff is about to begin.
however, take a look at the valve guide on the right. its smooth and different to the other guide, given that the manual images show that both valve guides are supposed to be the same, with groves to hold the stem seal etc. but this is doesnt have those groves.

Does any one have some feedback? who knows what has been done by previous owners.
Do you think i should buy a new valve guide and replace this plain one, so it will match the other. or perhaps this is standard? i cant find any info about it.

i hope this is clear. any help would be great.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 10, 2017, 07:26:35
Yay!!!!! new piston rings have arrived, just setting the gaps at the moment before i install the rings.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 12, 2017, 20:49:19
Im super excited about the process at the moment, building and putting the bike back together is going to be awesome.
cleaning parts and re greasing at the moment, The swing arm components where all in great condition, they were just dirty and had 30 year old grease on them. cleaned everything and replaced what was needed. I just put the swing arm back together and its so solid and smooth now.

I moved my work desk in front of my timber shooting board, now i have no where to fire pucks! sucks.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 28, 2017, 08:02:45
Parts arrived so started putting the engine back together, new rings and honed cylinder

i dont know why my pictures are sideways.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 28, 2017, 08:12:05
Completely rebuild wheel hubs, new pads, new bearings new clean grease, should be sweet
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 29, 2017, 04:43:15
I just had the new valve lapping done, installed the new valves and new springs. nice and clean looks good. pretty happy so far.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 13, 2017, 06:52:20
Finally got a new bolt to hold the Camshaft on,
and realised something is horribly wrong with the camshaft. its missing or has snapped off a guide that holds the sprocket on straight. its not there.
So the sprocket doesnt sit on and has heaps of movement. Wish i have know this ages ago.
So now its time for a new camshaft. sucks. more delays!
Title: Re: 1980 XT500 BUILD
Post by: hillsy on Jun 13, 2017, 20:35:18
Finally got a new bolt to hold the Camshaft on,
and realised something is horribly wrong with the camshaft. its missing or has snapped off a guide that holds the sprocket on straight. its not there.
So the sprocket doesnt sit on and has heaps of movement. Wish i have know this ages ago.
So now its time for a new camshaft. sucks. more delays!


That's weird - looks like the shoulder snapped off and the PO dressed the face to run it with just the bolt and the pin.


A bit ghetto, but probably worked OK....
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 13, 2017, 21:39:45
Yeah mate, your spot on. I tried putting it back together with just the bolt, just to see if it worked , I would never run it like that, but just out of interest, and the sprocket moved side to side. So needless to say I need a new camshaft.
Thanks for the reply! Hasn't been much conversation on my posts so far. So I appreciate it.


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Title: Re: 1980 XT500 BUILD
Post by: hillsy on Jun 13, 2017, 22:38:25
Been thinking about pulling out my old XT and re-doing the top end (it's been in the corner of the garage patiently awaiting it's turn).


Your thread is giving me some inspiration  8)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 13, 2017, 22:47:04
Hahah!!! Woooooo!!! Get it out man! Xt's are sick!! Fire that thumper up!
I can't wait till mine is done.
My thread will start to get less boring now as I do the rebuilt with shiny new parts


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Title: Re: 1980 XT500 BUILD
Post by: daffysaurs on Jun 19, 2017, 17:50:46
Stumbled across your XT rebuild today. Looking great.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 19, 2017, 19:52:43
Stumbled across your XT rebuild today. Looking great.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 19, 2017, 19:54:27
Thanks mate!
Going a little more slowly than I wanted because waiting for parts take a while, but it should get more exciting this week, I'm picking up the wheels today, they have just been re-spokes and powder coated! Can't wait


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Title: Re: 1980 XT500 BUILD
Post by: Popeye SXM on Jun 19, 2017, 20:15:09
Hi I just found this. I rode a bike just like your's when I was in OZ 20 years ago. I have been a fan of XT's ever since. Looks like you are doing a great job. Enjoying the build, keep posting the pics please
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 19, 2017, 20:31:13
Awesome Popeye!
Thanks for the feedback. Be ready for some pics this week.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 20, 2017, 06:02:44
Hey everyone, Just picked up the wheels from being re spoked with new spokes.
powder coated the rims and hubs. looks pretty good.

Shopping for tyres tomorrow! yay! im going to try and get a dual tyre. Something i can ride on road and off road. For some adventures and exploring. Stay tuned to see what i come back with!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 22, 2017, 06:19:14
I had the forks painting gloss black,
got some new fork gaiters and i have just drained all the old fluid and replaced with new fluid.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 22, 2017, 06:28:36
So well at least its starting to look like a motorcycle again. Im currently waiting for a new cam shaft to arrive, so while im waiting i might as well put some of the steering head and forks back together.

I put new tapered bearings in the steering and it feels great, very very smooth. New risers and to be honest im super happy how its starting to look. nice and clean. Cant go wrong with black on black

I bought some new Renthal bars (silver to break up all the black) and could not resist putting them on and start making motorbike noises!!! braap! braap! braap!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 26, 2017, 07:11:24
ok great news.
the new camshaft has arrived, so i will be reinstalling the new one today.
everything went well and installed with no issues.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 26, 2017, 07:18:12
Ok so i need some advice please.

I am not sure how to install the cam chain tensioner, perhaps im over thinking it. im not sure how tight it needs to be.

so i just screwed the smaller one all the way in.
please have a close look at the pic, you will see what i have done. what is the general rule when installing these cam chain tensioners.

Any help would be great, thankyou in advance.
Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jun 26, 2017, 08:21:06
The smallest part in the very center is a floating rod.  The 10mm nut outside of it is the adjuster.  The big nut is the lock nut.  You're not going to over tighten the 10mm to start, but when the bike is running you adjust it until the floating rod bounces 1 - 2mm.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 26, 2017, 17:11:52
Hi miller , that's great thanks for the info.
When you say "bounces" do you mean it will twist back and forth 1-2mm?  And then I just adjust the 10mm nut either in or out until the rod does this?


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Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jun 26, 2017, 18:25:31
When the motor is running, the center rod bounces in and out like a sewing needle.  If it's loose enough, it almost looks like it's going to shoot out.  So, you're adjusting until it protrudes no more than 2mm.  You can stick a wrench over it and it will tap the wrench.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 26, 2017, 19:14:43
Ohh ok. Awesome, that is very helpful and a Great description. Thanks mate.  Wish me luck!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 27, 2017, 07:00:50
Ok here is todays update:
I installed a new upgraded oil line today, its suppose to feed more oil directly to the rocker arms.

I set the valves at:
Inlet valve: 0.09mm
Exhaust: 0.15mm

(Instructions from the oil line packaging say that because the engine will be cooler. Exhaust should be 0.12mm but i dont have a 0.12 feeler guage. mine skips from .10-.15)

If anyone has any thoughts on these valve clearance settings please let me know.

(ignore the gasket silicon, when it dries i will be pulling the excess off)
Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jun 27, 2017, 08:30:10
Spec is .07mm - .12mm on intake and .12mm - .17mm on exhaust.  So, you're in the wheelhouse.  I'd get one of these so you always have it to check.

http://www.ebay.com/itm/Motion-Pro-Tappet-Feeler-Gauge-004-005-10mm-13mm-08-0053-/182455268719?epid=917019082&hash=item2a7b2e756f:g:wpIAAMXQlgtRoAsd
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 27, 2017, 08:45:04
Yeah cheers mate.
You think it will still be ok with the clearance I have done


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Jun 28, 2017, 11:49:00
Looking good! What cam did you end up going with?  BTW, I've got an 81 XT500 and love it.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 28, 2017, 17:10:08
Hey mate, I just replaced with a stock standard cam for now. So I can get the bike back together.


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Jun 28, 2017, 18:03:41
Cool.  I am thinking about getting a new cam but haven't decided which one to get. 

Chrs!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 28, 2017, 18:09:46
Yeah, I have seen there are a few options for cams. Bottom end/mid range etc. it's a tough one to decide on. What issues do you have with your bike that your looking at buying a new camshaft for?


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Jun 28, 2017, 20:25:47
No issues really, just hoping for more/different power. I've got a high comp piston in it now with a VM36 carb.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 28, 2017, 21:15:11
Ok great that sounds awesome. Later on I want to put a bit bore kit in. Take it to 600cc. I have heard they really wake up! So later on I will most likely give it that upgrade. Need to do a lot more research before that though.


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Title: Re: 1980 XT500 BUILD
Post by: Eleganten on Jun 30, 2017, 14:19:41
(https://uploads.tapatalk-cdn.com/20170630/e82c0d84a6ec78cc3036b9b4cd9f3830.jpg)

This is what happens if you run a cam shaft without the guide. The pin isn't strong enough and it will start to brake of. Picked this one out of my newly rebuilt engine after it seized the second time. Hadn't  looked at the cam shaft since it looked all right when I installed it. Also it was a pain to get it started since the cam doesn't move like it should.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jun 30, 2017, 18:50:09
Wow! Thanks for your input and the photo. Do you think it's a common issue with this engine?



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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 01, 2017, 05:41:13
Just Arrived a new headlight and new tiny switch and button for the handlebars.
I will use this switch on the left side of my bars for my indicators and my horn.
I have always wanted to try feeding the wire through the handlebars, so this bike is a good opportunity to do this.

I will update as i go with other electrical bits i will be moving.
Title: Re: 1980 XT500 BUILD
Post by: Eleganten on Jul 01, 2017, 10:11:56
Well, to me it looks like a weak construction but it shouldn't have to take any loads to talk about. I've hade this braking down and the ratchet wheel on the kick starter axle. I think that the issue lies more with the fact that we are talking about 35 year old engines that's had several owners over the years. The XT/TT models probably also lived their lives a bit harder than the regular SRs. Over all I think the engines are solid pieces of Japanese engineering and as long as you keep them maintained and don't abuse them to much they are good for well over 100,000 Km. My bike has about 65,000 Km on the clock and the gearbox, clutch and lower end looks good, at least when inspected visually.

Bottom line, if you do take care of your bike it should be around for at least 25 years more.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 13, 2017, 04:27:31
hi everyone, I had just put of the new headlight and and starting to play around a bit with the handlebars, to see how everything is going to sit, Turns out my headlight depth is too large, so i need to get longer headlight brackets, because it hits the steering lock when you turn the bars.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 13, 2017, 04:37:22
Hello again, Today i was starting to install the wiring loom so i can see if there are any further adjustments i need to make, i also wanted to see if the battery box will fit everything, and its also great to see how the layout should be for the battery and other components.

I have a question for everyone!

Does anyone have any issues with having the rectifier inside the battery box as per the picture. As i do some research some people believe its better to have it on the outside so it can get air.
What are your thoughts?
Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jul 13, 2017, 08:36:08
Overheating kills them.  I'd put it outside.
Title: Re: 1980 XT500 BUILD
Post by: teledan on Jul 13, 2017, 10:21:28
I put mine under the tray for two reasons

1. To keep it cooler
2. I ended up just not quite having enough room in my tray for it :)

(https://s6.postimg.org/3slcg0cc1/2015-08-13_18.53.08_zpsgz2etrtp.jpg) (https://postimg.org/image/8ehgocxv1/)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 13, 2017, 16:57:42
Yes ok, thanks for the replies guys. I would obviously prefer to keep it in the battery box, but there is no point having something looking aesthetically pleasuring when it's not functional. I might try and play around and find a spot for it on the outside of the box. 


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Jul 13, 2017, 17:07:41
Would it fit on the front side of your tray?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 13, 2017, 17:53:17
Yeah that is exactly the spot I was thinking, on the front outside of the box just to the left of where the seat bracket clips in under the tank. I will have a little look today. But I feel that is best possible solution.


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Title: Re: 1980 XT500 BUILD
Post by: Jax12 on Jul 17, 2017, 05:22:48
(https://uploads.tapatalk-cdn.com/20170717/a48630fba801508cd4771b30003c405c.jpg)

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Title: Re: 1980 XT500 BUILD
Post by: Jax12 on Jul 17, 2017, 05:27:26
This is a build that me and my dad are working on almost done

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 17, 2017, 06:47:17
Awesome mate, love it! Looks great. Do you have a thread for it?


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jul 23, 2017, 05:47:42
Just put the rear wheel on and installed the new shocks. looks nice and clean.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 01, 2017, 04:08:02
Hi Everybody,
i must apologise i haven't updated everyone and havnt been uploaded anything,

The reason is I broke my leg and im on crutches for 6 weeks so its making it very difficult to get around and do anything,
Im going to try my best to continue on as normal. So i will now start to do some fiddly bits like wireing, mostly things i can do while sitting down.

Check out the new battery and wiring box for under the seat i made, The holes are for the kill switch i will install, the other hole is so the wiring can get to the rectifier which will be on the front outside of the box.
I have internally lined the box with a dense foam so the battery etc doesnt bounce around when im doing back flips.
Let me know your thoughts!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 06, 2017, 07:07:57
Hi guys, i had a bit of playing around with some wiring today,
I was super keen to see how this switch block would turn out so here it is, Would love to here your thoughts.

This is setup for my blinkers and my horn, I do have to have 2 more switches for my headlights, they will go into the back of my headlight case. that is still to come.
Title: Re: 1980 XT500 BUILD
Post by: Luugo86 on Aug 06, 2017, 13:00:00
Nice and clean.
Title: Re: 1980 XT500 BUILD
Post by: Popeye SXM on Aug 06, 2017, 22:51:42
Clean and tidy I like it 8)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 06, 2017, 23:02:59
Awesome !

Thanks guys
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 16, 2017, 03:58:25
So i am trying to sought out this mess of wiring. i was on a good roll and everything was working out.
But now im starting to get a bit stuck. So i might need some help.

Let start with the kill switch and horn.
I already have the wiring diagram from the manual. so that has helped.

I have a new kill switch, its the black switch in my hand.
-It has 2 prongs on the back. obviously 1 prong will connect by wire making its way to the coil. Would the other prong just need to earthed to the frame?
-The next issue, my new horn button, it has 2 wires. but the xt500 harness has only 1 pink wire. Do i need to just earth the other wire from the button to the frame.

I have other issue, but lets try to solve this problem first.
thanks in advance!
Title: Re: 1980 XT500 BUILD
Post by: TranceMachineVienna on Aug 16, 2017, 06:57:09
Hi guys, i had a bit of playing around with some wiring today,
I was super keen to see how this switch block would turn out so here it is, Would love to here your thoughts.

This is setup for my blinkers and my horn, I do have to have 2 more switches for my headlights, they will go into the back of my headlight case. that is still to come.

Thats looks amazing!may I ask where you got these switches from?
did you build it on your own?

Cheers!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 16, 2017, 07:10:04
Thats looks amazing!may I ask where you got these switches from?
did you build it on your own?

Cheers!




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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 16, 2017, 07:13:48
Hey mate, I bought it from modernmotorcylecompany. They are in Melbourne, they have awesome gear I have bought so many items from them before, always awesome quality and awesome helpful staff.


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Title: Re: 1980 XT500 BUILD
Post by: hillsy on Aug 16, 2017, 09:05:16


I have a new kill switch, its the black switch in my hand.
-It has 2 prongs on the back. obviously 1 prong will connect by wire making its way to the coil. Would the other prong just need to earthed to the frame?



Yes - the original kill switch grounds the wire from the coil to the bars so you need to do the same to make the new switch work.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 16, 2017, 18:26:47
Ok awesome , and I would assume I need to do the same with the horn button. That's great thanks for that! 


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 17, 2017, 05:01:18
Hi guys, well because the response was so fast and i solved the issue in regards to my last problem. im going to see if we can now fix this problem.

Does anyone know what these wires are for?
They are at the headlight end. I need to know what the 4 in my hand do. and also the 6 in the connection individually. I think the connection is for the handlebar switch block. But i need to know which wire does what.

Again any help would be great.

Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 24, 2017, 08:26:27
Anyone got any ideas about this wiring issue i have?
finding a wiring diagram that matches my wires is so hard, i  have found some that are close but none the same.

Any help would be great!
Title: Re: 1980 XT500 BUILD
Post by: teledan on Aug 24, 2017, 10:51:13
Is this a new aftermarket wiring harness or is this the stock harness?  Did you cut the three wires on the bottom of that white connector or were they already cut before you got it?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 24, 2017, 18:18:23
Hey mate, no this is a brand new wiring loom from kedoparts. The one with the ignition has 2 connectors.
The reason those wires are cut because they go to the blinker switch. And I'm pretty certain the other wires that are not cut in the connector go to the headlight/hilo switch. But don't know what goes where. And the ones in my hand. I have no idea. Must be the headlight but I don't know what is what.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 24, 2017, 21:48:44
check out my new headlight also,
this didnt come with a diagram, and my mind is a little rusty when it comes to wiring.

Anyone know what is what with these headlight wires? pos/neg etc
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 25, 2017, 00:17:52
In the meantime of me pulling my hair out about the wiring.
I had my exhaust sandblasted! It was in very bad shape. Nice and clean now.
Title: Re: 1980 XT500 BUILD
Post by: hillsy on Aug 25, 2017, 00:21:32
check out my new headlight also,
this didnt come with a diagram, and my mind is a little rusty when it comes to wiring.

Anyone know what is what with these headlight wires? pos/neg etc


Probably Honda wiring - they used green as a ground. So the other two would be low or high beam +ves.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 25, 2017, 00:27:49
Hey hillsy,
thanks mate, i will have a play with it. what does +ves mean?
Title: Re: 1980 XT500 BUILD
Post by: hillsy on Aug 25, 2017, 00:34:43
Hi guys, well because the response was so fast and i solved the issue in regards to my last problem. im going to see if we can now fix this problem.

Does anyone know what these wires are for?
They are at the headlight end. I need to know what the 4 in my hand do. and also the 6 in the connection individually. I think the connection is for the handlebar switch block. But i need to know which wire does what.

Again any help would be great.


Found a wiring diagram that might help:


(http://i279.photobucket.com/albums/kk159/bill_badger/wire_diagram_XT500D1977.jpg)


Yellow = hi beam indicator light
Blue  = tachometer lamp
Green/Yellow = front brake switch
Blue/Red = pilot lamp (in headlight)



Title: Re: 1980 XT500 BUILD
Post by: hillsy on Aug 25, 2017, 00:35:22
Hey hillsy,
thanks mate, i will have a play with it. what does +ves mean?


+ves means the positives for either hi/lo beam - they share the -ve.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 25, 2017, 00:40:16
thanks for your help mate, i have this diagram also, its not correct with my wiring loom. also the brake switch wires are accounted for.
Title: Re: 1980 XT500 BUILD
Post by: dakine_surf on Aug 25, 2017, 06:12:08
The bulb connectors prongs should be labeled if you pull the connector


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Aug 25, 2017, 08:44:52
Nah they arnt, but that's ok I solved the issue of the bulb wires. I just tested it on the battery so now I know what wires do what for the bulb.
Sorry everyone I should have done that in the first place.

I'm still stuck with all the other wires.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 04, 2017, 04:36:11
Rather than me throwing hammers in the garage because i cant figure out the wiring,
i have started to make a small bracket to hold the speedo.
Title: Re: 1980 XT500 BUILD
Post by: Luxy33 on Sep 10, 2017, 01:36:34
So good to see this coming along 👍🏼
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 10, 2017, 03:49:45
Just installed the rear brake switch, i was waiting for the bracket that holds the brake switch,
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 19:16:10
I installed that bracket i made for the new speedo, its sits perfect, clean and low. pretty happy with it.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 19:18:36
I have been trying to buy a new rear brake arm for the rear drum break, because the one i have is destroyed, i havnt had any luck buying a new one, so i am going to have to try and fix this one i have.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 19:21:39
the rear brake arm worked out ok, after a few hits with the hammer and the angle grinder. I slapped some new paint on there, and bought a new spring. looks ok and im sure it will work great!

What are your thoughts?
Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Sep 28, 2017, 19:23:56
the rear brake arm worked out ok, after a few hits with the hammer and the angle grinder. I slapped some new paint on there, and bought a new spring. looks ok and im sure it will work great!

What are your thoughts?
Looks good. You followed the tried and true method of hammers and angle grinders. If you start there you cant go wrong. The hubs, spokes and rim combination looks great.

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 19:29:41
Probably the biggest challenge i have had so far is redoing all the wiring, given the way the wiring was, i will feel so much more comfortable rewiring the entire bike. knowing that every connection and wire is solid and connected properly will make me feel way better.

Most of my delay with my posts have been because i have been trying to figure out the wiring, but I have made some great progress understanding the wiring. So im kicking goals now!
Title: Re: 1980 XT500 BUILD
Post by: 540Nova on Sep 28, 2017, 20:43:02
Looks like good quality environmental splices there.
One thing you'll find, like I did, is the Hi beam indicator on that speedo is BRIGHT! So much so, that I put a piece of tape on it at night, because it kills my night vision!

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 23:17:46
Looks like good quality environmental splices there.
One thing you'll find, like I did, is the Hi beam indicator on that speedo is BRIGHT! So much so, that I put a piece of tape on it at night, because it kills my night vision!

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Yeah your right, it is super bright, i have the exact same speedo on my Triumph.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Sep 28, 2017, 23:18:44
Looks good. You followed the tried and true method of hammers and angle grinders. If you start there you cant go wrong. The hubs, spokes and rim combination looks great.

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Haha yeah thanks mate, I feel there is nothing that canít be solved with an angle grinder and hammer!!!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 04, 2017, 05:44:30
Its always awesome when the last person that owned the bike just thought it was a super idea to weld the clutch foot lever on.
Great for him but a nightmare for me, trying to get it off was a killer.

Installing the new one turned out ok though. 
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 04, 2017, 05:48:34
I popped in the engine! woooooooooo getting exciting now.

What does everyone think so far?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 04, 2017, 05:54:50
I put the oil pan back on. If you flick back to the start and see the oil pan when i first took it off. man what a difference!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 04, 2017, 07:17:17
Oh and by the way!
i still have no idea what these wires are for. (they are in the headlight)

Everything is working,
however my brakes lights are not working, rear brake doesnt do anything, and front brake when pressed, the brake lights turns off. i know its weird, so i still have some wiring issues to deal with.
any help would be great
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 07, 2017, 06:22:31
Ok good news after playing around with the wires some more, i now have everything working great!

So glad the wiring is under control.

Time to move onto painting and resembling the kick start!
And do some welding for the side stand.
Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Oct 07, 2017, 17:01:56
Coming along very nicely!

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 07, 2017, 18:57:30
Coming along very nicely!

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Cheers mate!


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Oct 07, 2017, 22:01:16
What is the plan for the finished bike? Enduro/off road, stress tracker or something else?

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 08, 2017, 01:32:48
What is the plan for the finished bike? Enduro/off road, stress tracker or something else?

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As soon as the bike is finished. Iím throwing on a backpack and heading down to great ocean road and hitting the enduro tracks of Anglesea and ending up where ever the trails take me!

Then Iím also going to try and join the vinduro circuit guys and see if I can fang around with them.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 08, 2017, 15:46:50
Also going to club reg the bike for on road and enduro


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Oct 08, 2017, 16:18:09
Solid plan. I love the tracks around Anglesea. I ride my dirtbike around there, fast sandy trails and some good single track too.

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 16, 2017, 06:55:32
Just repainted and installed a new rubber end. for the kickstart.
bought a new spring and balls for the kick start assembly. should work great.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 17, 2017, 05:40:59
New washer, ball and spring arrived today.
So i painted the kick start, put on a new rubber, a little bit of grease. and its looks great, and even better its so smooth now, it was all rusted up and didnt move when i got it.

What do you think?
Title: Re: 1980 XT500 BUILD
Post by: hillsy on Oct 17, 2017, 09:13:19
Nice  8)


Now you have to paint the brake lever....and the kick starter clamp....and the..... ;D
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 19, 2017, 07:19:53
A few shiny parts arrived today. I have put on a pod filter, and was super worried the wiring/battery box was going to get in the way.
But it fit perfectly. looks great.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 19, 2017, 07:33:07
Just installed the new brake light and number plate bracket
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 19, 2017, 07:44:31
I have removed the old decompression leaver from the handle bars, and replaced it with this new decompression lever.

Less is more!

Any opinions?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 21, 2017, 23:02:10
I just filled the bike up with oil today.

I have a question.
When does the oil pump start working? when the bike starts? because im concerned about trying to kick start the bike without knowing if there is oil all through the engine.
I just filled it up, i will leave it for a day , hopefully thats enough time for the oil to work its way through.

Anyone got some advice about what i should be doing before i kick start this beast?
Title: Re: 1980 XT500 BUILD
Post by: 540Nova on Oct 21, 2017, 23:31:48
I just filled the bike up with oil today.

I have a question.
When does the oil pump start working? when the bike starts? because im concerned about trying to kick start the bike without knowing if there is oil all through the engine.
I just filled it up, i will leave it for a day , hopefully thats enough time for the oil to work its way through.

Anyone got some advice about what i should be doing before i kick start this beast?
Oil is only going to begin to flow when the engine is running. You won't harm it by kickstarting it.
No benefit to sitting over night, oil only goes to the lowest point in the engine, almost immediately upon pouring it in.

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Oct 22, 2017, 00:16:15
Oil is only going to begin to flow when the engine is running. You won't harm it by kickstarting it.
No benefit to sitting over night, oil only goes to the lowest point in the engine, almost immediately upon pouring it in.

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Ok great, thanks for the advice!!! You have been a great help


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 01, 2017, 07:26:33
Im just waiting for some new parts to arrive, hopefully tomorrow or the next day,
will have some updates soon! and will start to fire this baby up!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 01, 2017, 21:17:23
ohhhhhhhhhhhh the door bell rang!!!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 01, 2017, 21:22:43
New parts arrived, cant wait to put this exhaust on!
with have updates shortly.

any thoughts?
Title: Re: 1980 XT500 BUILD
Post by: hillsy on Nov 01, 2017, 22:21:43
SuperTrapp? Looks nice.


If it's too loud you can wrap the insides with wadding. I put one on my old cruiser - it was nice because you could add / remove plates to tune it  ;)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 01, 2017, 22:48:20
Yeah im just have a play around with it now, its becoming very annoying. and i really am struggling to find a way to install it where it wont rub the tire too much.
also all the information/instructions they sent are in german, so that is a huge help, considering i dont speak german, so most of the bolts etc i have no idea what they are for.
Mounting it i can already tell is going to be a challenge. 
Title: Re: 1980 XT500 BUILD
Post by: Pete12 on Nov 02, 2017, 06:01:48
Yeah im just have a play around with it now, its becoming very annoying. and i really am struggling to find a way to install it where it wont rub the tire too much.
also all the information/instructions they sent are in german, so that is a huge help, considering i dont speak german, so most of the bolts etc i have no idea what they are for.
Mounting it i can already tell is going to be a challenge.

You'll work it out, you've sorted everything else out up until now.
Good work so far, you'll have a nice bike when you're finished
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 02, 2017, 06:11:01
Oh thanks mate, really appreciate it!
thankyou for the support
Title: Re: 1980 XT500 BUILD
Post by: CrabsAndCylinders on Nov 02, 2017, 16:52:59
You could also type the German instructions into Google and translate.  They won't be exact but might help.  Just don't mention the war.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 02, 2017, 17:00:56
You could also type the German instructions into Google and translate.  They won't be exact but might help.  Just don't mention the war.
Haha thanks mate, I have asked kedo to send me the English instructions. Still waiting.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 05, 2017, 19:48:43
Well after i played around with  my muffler, i realised that my stock exhaust pipe will not do, because for some reason, the previous owner, cut the pipe and put on some sought of extension.
Anyway who cares!

So i bought a new pipe.
Im still waiting for kedo to send me some english instructions, which i doubt are ever coming. Sooooooooooooo does anyone know where these 2 rings go? or what they are for?

Any help would be great.

Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 03:57:11
In regards to the new exhaust and pipe, it really didnt fit all that well, so i have had to make up a new bracket to hold the exhaust in place,
as im sure most of you are aware there is absolutely no room for exhausts and mufflers on the XT, its so tight. I personally, on this bike am really struggle for room, so i have had to adjust some things. It may work for other people on there bikes, but for this build the exhaust wasnt fitting very well, without having problems late with the tyre rubbing.
So this bracket i made with solve that issue. I know it looks horrible now, but i will paint it and shape it better, im just seeing how it will fit, and turns out it works great.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 04:05:21
So here is the bike so far.

What do you think?

Its ready for some fuel and lets get it started and running!!!!!!

From here on, im going to need some help. getting the bike started and tuned.

What are my first steps to getting it started.

The bike has spark and fuel. i should probably check my points plate it set correctly. Anyone have any Advice?? 
Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 06, 2017, 07:23:43
Love it. Looks great. As for starting it, fuel, choke, then start kicking!

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 16:36:47
Love it. Looks great. As for starting it, fuel, choke, then start kicking!

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Thanks Mate, wanted to go into a bit more detail than that hahah.

I have been kicking but no luck, time for some troubleshooting.


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Title: Re: 1980 XT500 BUILD
Post by: CrabsAndCylinders on Nov 06, 2017, 16:37:32
Thanks Mate, wanted to go into a bit more detail than that hahah.

I have been kicking but no luck, time for some troubleshooting.


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Keep the throttle closed when starting.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 17:05:38
Keep the throttle closed when starting.

Yeah I have been doing that, I think I need to check the static timing.
Iím pretty sure itís correct, but while kicking it, it doesnít sound like it wants to start at all.


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 06, 2017, 17:10:33
Thanks Mate, wanted to go into a bit more detail than that hahah.

I have been kicking but no luck, time for some troubleshooting.


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I like to keep it simple. It's a big single 4 stroke. It's not going to be fun to kick over. If you have good spark, fuel & air flow, ignition timing set correctly, valve timing correct then you should be good to go. Make sure that the piston is at top dead centre before kicking.
Make sure you have your boots on too....

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 17:26:22
hahha yeah dont worry, i know i have to have boots on for sure!!!! still recovering from a broken leg , so im super sensitive with my limbs at the moment.

I think everything is set. ill give it some kicks today and let you know how i go.

I am wondering if i have set everything correct. I hope so
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 06, 2017, 21:33:03
ok ive been kicking and kicking, something is up.

Take a look at my points plate, while on the F mark.

any thoughts, or any opinions on what else i should check or adjust,

I have spark and fuel
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 00:53:34
ok ive been kicking and kicking, something is up.

Take a look at my points plate, while on the F mark.

any thoughts, or any opinions on what else i should check or adjust,

I have spark and fuel

Ok great result !!! It fired up! I adjusted the points plate a little bit. And it fired up.
I noticed an air leak in the exhaust, so I will adjust that now.

It ran for a bit, but didnít sound all that strong.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 01:20:03
Ok now I have a new problem. My battery is draining. Iíve had to recharge it twice.

Why would the bike be draining my battery?


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 05:16:49
ok so my update after today, i think its an electrical issue, i have no idea why my battery is not charging and is going flat.

Also check out my spark plug, i think its running too rich. a quarter turn out of the mixture screw might fix this.

Anyone know why my battery is going flat? its a new battery, but lasts like 4 minutes. even while the bike is running
Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 07, 2017, 11:23:33
Could be your regulator is bad.  What is the voltage at the battery terminals while the bike is idling?  What about if you rev it up a bit?
Title: Re: 1980 XT500 BUILD
Post by: teazer on Nov 07, 2017, 13:38:19
Ignore what the plug looks like.  Reading plug color really only applies to WFO ie flat out under load.  That doesn't tell you anything about idle mixture.  Set idle mixture to give you the highest idle speed and the best response as you crack open the throttle. Anything else is a distraction at best and misleading at worst.

Fix the electrical system first and then set points gap and timing and after those are spot on, then think about tweaking the air screws.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 15:09:47
Ok teazer, cheers mate, I will do that. Great advice.
I have a new regulator, but I have converted from 6v to 12v, so something is definitely wrong with the electrical system. The battery shouldnít be draining so fast. And I feel thatís why itís so hard to start. 


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 07, 2017, 15:53:13
Ok teazer, cheers mate, I will do that. Great advice.
I have a new regulator, but I have converted from 6v to 12v, so something is definitely wrong with the electrical system. The battery shouldnít be draining so fast. And I feel thatís why itís so hard to start. 


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How did you convert to 12v? Did you buy a kit or DIY?

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 16:51:59
Yeah I bought a Rexís speed shop 12v XT500 conversion kit.


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 07, 2017, 17:33:50
Yeah I bought a Rexís speed shop 12v XT500 conversion kit.


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I'm looking at one of those for my DT. Maybe contact them and see if they have any solutions.

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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 07, 2017, 17:35:36
Yeah, Marcus is very helpful.  This should not affect starting though, you don't need a battery to start these bikes.  I am actually running a capacitor instead of a battery on mine and she starts up just fine.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 17:46:13
You donít need a battery to start a XT500?? Are you sure thatís correct.
I have tried contacting them, no one every replies to me.


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Title: Re: 1980 XT500 BUILD
Post by: doc_rot on Nov 07, 2017, 17:48:43
pretty sure these bikes use the battery as a capacitor and wont run well or at all without one even if you kick-start
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 17:50:33
Yeah I think it needs the battery, because I could only start the bike when the battery was full, it wouldnít start or even sound like it wanted when the battery was getting flat.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 17:51:25
Another side note, the bike would not idle with the choke off. It would die out.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 18:39:20
Another side note, the bike would not idle with the choke off. It would die out.


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Do we think that maybe my generator isnít working?



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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 07, 2017, 18:57:38
The ignition circuit and the lighting circuit are separate.  If you are running lights you definitely want a cap or battery but the ignition doesn't rely on it to start. Don't forget the TT500, they didn't use a battery/cap at all.
Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 07, 2017, 18:59:59
Do we think that maybe my generator isnít working?



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It is possible.  There is a troubleshooting guide for the 12v conversion kit on this page:

http://www.rexs-speedshop.com/epages/es143131.sf/en_GB/?ObjectPath=/Shops/es143131/Categories/Tech_Support
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 19:18:09
Awesome , thatís for the great info, I have just been reading through the Rexs paper work, and I have just realised I have a led tail light. I doubt that would be causing the problem. I think I need to test if the generator is working. Thanks for the help I really appreciate it.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 21:18:01
Does anyone have any tips to why the bike would be turning off when I turn the choke off?
Perhaps I need a bigger pilot jet? Considering I have a pod filter.


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 07, 2017, 21:40:05
Could be too small pilot jet, or mixture screw not adjusted quite right.  Remind me again, what carb are you running? And what size pilot jet do you have now?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 07, 2017, 21:55:07
Let me check and Iíll get back to you


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 08, 2017, 01:24:16
Ok so i have VM34SS carb.
I have a 210 main jet and a 35 pilot jet.

Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 08, 2017, 01:45:44
Also i would like to add, that yes the bike does start and run without the battery. i just kick started the bike without the battery attached, and all my lights etc were working without the battery attached.

So do you think that this tells me that the generator is working ok?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 09, 2017, 19:12:09
So I have an update, once the bike is started if I give it a little pull of the throttle is does back fire a bit. Also backfiring from the pod filter. I have checked the timing with the strobe light and f mark is not exactly on the line, the f mark is about 5mm before the line. So how can I adjust this?


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Title: Re: 1980 XT500 BUILD
Post by: XS750AU on Nov 09, 2017, 20:33:05
Don't have an XT500, but from your previous photo it looks like
Refer to attached photo.
Loosen screws A & B (do not remove)
Use a blade screw driver in position C to then rotate the ignition base plate to advance or retard the spark timing (not sure which way retards or advances but you will soon work it out)
If you leave enough drag on the screws A & B then you should be able to tune the timing while the motor is going, which makes it easier!
Hope this helps.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 09, 2017, 22:03:47
Don't have an XT500, but from your previous photo it looks like
Refer to attached photo.
Loosen screws A & B (do not remove)
Use a blade screw driver in position C to then rotate the ignition base plate to advance or retard the spark timing (not sure which way retards or advances but you will soon work it out)
If you leave enough drag on the screws A & B then you should be able to tune the timing while the motor is going, which makes it easier!
Hope this helps.

Thatís great info, thankyou I will do that,
Do you think the poping and backfiring is generally because the timing is off?

I still have a lot of problems starting the bike, but I think it may be because Iím getting used to kick start, all my other bikes are push start.




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Title: Re: 1980 XT500 BUILD
Post by: XS750AU on Nov 09, 2017, 22:19:59
Timing will absolutely make it difficult to start and also cause the backfiring.
From looking at the witness marks on your backing plate, it looks like screw A should be somewhere in the zone marked up in BLUE. You are currently at one extreme of adjustment so I suggest you go the other way. There looks like a heavy mark at the end of the BLUE zone which is where I would move it to and then start your fine tuning.
Just crack the screws loose, so you can just move the plate by using a blade screwdriver in location "C".
Good luck
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 09, 2017, 22:35:33
Thatís great I will do that today, and repost an update, thankyou for support and information.

Now I just have to figure out how to start it more consistently in order to work on these things


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 10, 2017, 22:50:29
Ok guys, so I canít start the bike with first kick when itís stone cold. But itís impossible to start the bike while itís warm.

I have adjusted the timing and now while running the f mark is spot on the line While checking with the strobe light. So thatís great.  But I am wondering , does it matter that I adjusted the timing while the choke was on? Because I cannot get the bike to continue to run unless the choke is on. I think i need a larger pilot jet. I have 35 pilot but I think I should get 37.5

Also does anyone know why, I can start the bike when its stone cold. But itís impossible to start while itís warm.


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 11, 2017, 00:02:22
Ok guys, so I canít start the bike with first kick when itís stone cold. But itís impossible to start the bike while itís warm.

I have adjusted the timing and now while running the f mark is spot on the line While checking with the strobe light. So thatís great.  But I am wondering , does it matter that I adjusted the timing while the choke was on? Because I cannot get the bike to continue to run unless the choke is on. I think i need a larger pilot jet. I have 35 pilot but I think I should get 37.5

Also does anyone know why, I can start the bike when its stone cold. But itís impossible to start while itís warm.


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I don't think that adjusting the timing with the choke on should cause any problems. Sounds like your fueling is out because of the air filter and exhaust. Are you sure that carb idol circuit is clean and not blocked?
Try adjusting the primary air screw fully in and fully out and see if it will start and run.

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Title: Re: 1980 XT500 BUILD
Post by: hillsy on Nov 11, 2017, 00:42:40


Also does anyone know why, I can start the bike when its stone cold. But itís impossible to start while itís warm?


Are you using the hot start button on the carb when you are trying to start it hot? It holds the throttle slightly open which helps when the engine is warm.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 11, 2017, 00:43:09
I don't think that adjusting the timing with the choke on should cause any problems. Sounds like your fueling is out because of the air filter and exhaust. Are you sure that carb idol circuit is clean and not blocked?
Try adjusting the primary air screw fully in and fully out and see if it will start and run.

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Ok great I will try that,
My carb is definitely clean, it has been hydro blasted and cleaned multiple times. In side and out.   


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 11, 2017, 01:12:22
Ok so I finally got it started just now, good thing is that the popping and backfiring is gone.
I did give it a few small revs and it was ok with small revs, but if I twisted the throttle a bit more it sounded like it wanted to cut off.
It finally did cut off when I turned he choke off.
I have a question for the hot start button, obviously you turn the button, but once you start the bike, would you turn it back to zero? What should the setting be for the hot start button?

Thanks for the help guys, I really appreciate it. Itís heating up in Melbourne and I want to be doing monos down the street! Cheers.


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 11, 2017, 01:18:54
It is a button that you press and it just slightly opens the throttle valve, then if you were to rotate the throttle the opposite direction it will push the button back up.
Title: Re: 1980 XT500 BUILD
Post by: XS750AU on Nov 11, 2017, 17:47:40
Hi
Sometimes ignition issues can appear as fuel problems. If you are using the stock carbi with a pod filter and possibly a more open exhaust then it should run but with a few flat spots, but it should start and run.
Have you checked that your points are set correctly? Is the gap (when points are open) set correctly? very important!!!
Have you replaced the spark plug lead? You may have spark but is it a strong spark? Poor spark and the engine will be hard to start and die when you open it up. All carbi tuning guides emphasis that you must have the ignition correct before you start changing jets.
Just some thoughts.  :)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 11, 2017, 18:14:44
Hey mate, yes so I have set the points gap correctly. .35mm , I have a new coil and lead with a new spark plug. The spark looks strong when I check it.

Like I say, first thing in the morning I can start the bike on the first kick. But once it shuts off, I can never start it again.


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 12, 2017, 02:41:09
Hey Guys,
I looking for some advice here, just wondering about the below image details.

Any help would be great, cheers
Title: Re: 1980 XT500 BUILD
Post by: Psycrow on Nov 13, 2017, 01:12:45
Mack,
Working on my own XT500 build. Not sure about A and C in the above pic but pretty sure B is the overflow drain not a vent or vacume line. I have a build thread over at xt500.co... there are some XT experts there that could probably help you as well. These bikes have a rep for hard starting when warm. Mine is doing that as well and with my older VM32 carb I have no hot start button. Ill watch this thread and as I get deeper into my own build Ill share any info I discover...
Yours looks very nice so far!! Im going to need new shocks so I was wondering what you picked up and in what length... like the look of them.

Psy

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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 13, 2017, 01:52:01
C is the vent for the stator area.  There should be a tube on it that runs back and down behind the motor.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 13, 2017, 01:54:58
Ok great thanks for that, so C doesnít connect to anything, just a hose that hangs behind the motor.


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Title: Re: 1980 XT500 BUILD
Post by: teledan on Nov 13, 2017, 02:00:07
Exactly. I donít have my stock carbie anymore so I am not sure what the other two are :)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 13, 2017, 02:02:04
Ok thanks for your help.


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Title: Re: 1980 XT500 BUILD
Post by: Psycrow on Nov 13, 2017, 03:05:49
MCKAY,

Also here is a site with some great info on the XT electrical system and cold and hot startup procedures... It helped me better understand these unique machines.

https://www.patu.ca

Psy

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 17, 2017, 23:10:38
Hey Psycrow,
thats awesome thanks for sending that to me, it has been a great help.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 17, 2017, 23:16:37
I have pulled the carbie off today to double check my main jet and also my pilot jet, I have ordered a #37.5 and a #40 pilot jet. and i have also ordered a #220 and a #230 main jet. So when they arrive i will have another play around.

I did actually notice on further inspection of the carb was that the floats were set at about 18mm, the yam book says 22mm. So i have adjusted that, the floats are now set at 22mm. 
Will be interesting to see if these changes will help at all.

I would love to here some feedback. cheers guys! everyone has been a great help so far.
Title: Re: 1980 XT500 BUILD
Post by: Psycrow on Nov 18, 2017, 07:32:35
Hey Psycrow,
thats awesome thanks for sending that to me, it has been a great help.
Glad it helped you it certinly helped me but thank Patu... hes a contributing member here... ;)

Psy

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 25, 2017, 01:11:28
Hey guys, I have a question, how can I check to see if my oil pump is working?


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 30, 2017, 17:23:13
Ok I have checked the oil pump, itís working fine.

Iím thinking maybe the problem is my carby, itís impossible to start when itís warm, and my spark plug seems dry, which means I donít think itís getting fuel. Iím going to put the carby in the ultrasonic cleaner today and give it another go, if I donít have any good results. I am stuck!!!


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on Nov 30, 2017, 17:33:38
Ok I have checked the oil pump, itís working fine.

Iím thinking maybe the problem is my carby, itís impossible to start when itís warm, and my spark plug seems dry, which means I donít think itís getting fuel. Iím going to put the carby in the ultrasonic cleaner today and give it another go, if I donít have any good results. I am stuck!!!


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Do you have a carb diagram to follow all of the fuel circuits and identify which one is causing the issue? There is also some XT and TT forums that have some carb info. With a different air filter and exhaust, you will most likely need to change the jetting. It might pay to look at a 6 Sigma or JD jetting kit.

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Nov 30, 2017, 18:13:01
Do you have a carb diagram to follow all of the fuel circuits and identify which one is causing the issue? There is also some XT and TT forums that have some carb info. With a different air filter and exhaust, you will most likely need to change the jetting. It might pay to look at a 6 Sigma or JD jetting kit.

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Hey mate, yes I have changed the jetting, I put a bigger pilot jet and main jet, also changed the  needle c clip.

Starting it when itís warm is a nightmare. And my spark plug is dry, so I feel itís not getting fuel.



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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 15, 2018, 05:48:06
Hey guys, sorry for the delay, i have been away. still having some issues starting the dam thing.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 23, 2018, 06:26:43
hello all , i was just wondering if anyone knows how easy or difficult it is to replace the Gear Shift Shaft for the clutch?
the thread is compliantly destroyed and must be replaced,

any help would be great and much appreciated
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 23, 2018, 16:35:11
to remove the gear shift shaft.
is this correct.
-drain oil
-remove cover, points etc
-remove boot and C clip.

after that, does the shaft slide right out? and i can just slide a new one in?

is it that easy? or an i being naive

any help would be great.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:24:08
Hey guys, so some new parts arrived !
I got the gear shift shaft , so it will be great to a put a new one of these in the XT.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:28:44
I didnt get much of a response in regards to replacing the gear shift shaft.
So if your interested , this is how i did it!

I drained the oil first, you have to remove the side cover, so i had to remove points plate also.

Im excited to get this done, i havnt replaced one of these before so i will learn something new!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:35:46
Well, ive learned the hard way!

So it appears after i removed the side cover, you do have to remove the clutch basket. Which means this will be a larger job than expected.
But thats no problem.

In actual fact! From what i can see if you only want to replace the shaft. you probably dont have to remove the whole basket, however in my case i bought a brand new gear shift shaft from KEDO parts, and there part comes all as one part, as in the PAWL is welded to the shift shaft.
Title: Re: 1980 XT500 BUILD
Post by: Nj732port on Dec 28, 2018, 19:39:53
Well, ive learned the hard way!

So it appears after i removed the side cover, you do have to remove the clutch basket. Which means this will be a larger job than expected.
But thats no problem.

In actual fact! From what i can see if you only want to replace the shaft. you probably dont have to remove the whole basket, however in my case i bought a brand new gear shift shaft from KEDO parts, and there part comes all as one part, as in the PAWL is welded to the shift shaft.





lookin good, im workin on my third sr and might pick up an xt if the guy comes down in price.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:40:38
I have removed all the plates and basket. No problems here, very easy and straight forward.

Behold the gear shift shaft!!!!!!!!!

time to remove it and through it as far away from my garage as i can!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:43:26
Out with the old
In with the new
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 19:48:59
Once the E-clip was taken off the shaft, it slides right out, and if you wanted to replace the shaft only, Ive noticed the whole clutch basket does not need to come off, because the shaft slides right out.

wanted to replace the o ring while im at it, on the gear pedal side.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 20:00:52
Yay!!!!!

New gear shift shaft installed, no problem. Notice how the shaft is welded to the gear change arm. so thats why i had to remove the whole clutch basket.

As the manual request, i put it into 2nd gear. and lined up all the marks. and adjusted the screw so all the marks matched.
So should be all good.

I did notice that my clutch plates where sticking together a bit. Rather than just sitting them in oil, I just ordered a new set of clutch plates and will install new ones.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 20:31:58




lookin good, im workin on my third sr and might pick up an xt if the guy comes down in price.




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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Dec 28, 2018, 20:32:40




lookin good, im workin on my third sr and might pick up an xt if the guy comes down in price.

That sounds awesome!!! Great engines and very fun bikes!!!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 01, 2019, 22:03:34
Hey Guys, just wondering if someone could help me.
does anyone know what Yamaha decal this is from? and if i can buy it from somewhere? I have been searching but i cannot find the exact style decal.

Any help would be appreciated
Title: Re: 1980 XT500 BUILD
Post by: teledan on Jan 01, 2019, 23:38:23
That looks to be a variation of the Yamaha ďspeed blockĒ pattern. You might try searching ďYamaha speed block decalĒ and see if you can find something similar.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 01, 2019, 23:53:43
Ok great, thanks for that, i will have a look.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 03, 2019, 02:47:33
Hmmm i have had no luck looking for the tank decal.
im wondering now if its a custom tank decal.

Your correct about the speed block decal, its very close!
Title: Re: 1980 XT500 BUILD
Post by: XS750AU on Jan 03, 2019, 05:14:53
This was the closest I could find.
https://www.ebay.co.uk/itm/YAMAHA-RD125-RD200-RESTORATION-DECAL-SET/163199995641?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D20160323102634%26meid%3Db182edc7d47b4611bbe8ab2d536bf69e%26pid%3D100623%26rk%3D4%26rkt%3D6%26sd%3D132320106158%26itm%3D163199995641&_trksid=p2047675.c100623.m-1 (https://www.ebay.co.uk/itm/YAMAHA-RD125-RD200-RESTORATION-DECAL-SET/163199995641?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D20160323102634%26meid%3Db182edc7d47b4611bbe8ab2d536bf69e%26pid%3D100623%26rk%3D4%26rkt%3D6%26sd%3D132320106158%26itm%3D163199995641&_trksid=p2047675.c100623.m-1)

With a bit of trimming it would be close.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 03, 2019, 06:32:56
This was the closest I could find.
https://www.ebay.co.uk/itm/YAMAHA-RD125-RD200-RESTORATION-DECAL-SET/163199995641?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D20160323102634%26meid%3Db182edc7d47b4611bbe8ab2d536bf69e%26pid%3D100623%26rk%3D4%26rkt%3D6%26sd%3D132320106158%26itm%3D163199995641&_trksid=p2047675.c100623.m-1 (https://www.ebay.co.uk/itm/YAMAHA-RD125-RD200-RESTORATION-DECAL-SET/163199995641?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D20160323102634%26meid%3Db182edc7d47b4611bbe8ab2d536bf69e%26pid%3D100623%26rk%3D4%26rkt%3D6%26sd%3D132320106158%26itm%3D163199995641&_trksid=p2047675.c100623.m-1)

With a bit of trimming it would be close.

Yes! I also found those RD decals. I think itís as close as Iím going to get. I think they will look great

Thanks for the help!!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 06, 2019, 03:45:16
Why i am waiting for parts to arrive. like clutch plates and a few other bits, i thought i would wrap the exhaust.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 06, 2019, 03:57:46
I just thought i would also add that earlier on in the rebuild, the bike was not starting. and i was having trouble. I realised that it was because it has low compression and it also had a faulty kill switch, because of the faulty kill switch the spark was very inconsistent .

So i had another fresh top end rebuild done. replaced everything! that fixed the compression issue. now the engine is absolutely perfect!!
Installed a brand new kill switch also.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 06, 2019, 04:03:20
Today, i noticed my rear sprocket was a bit wobbly. Not too bad but definitely some movement!
So i replaced all the rubber dampers and o rings and its now super tight and snug. So that fixed the issue if anyone else is having the same problem.
Title: Re: 1980 XT500 BUILD
Post by: teledan on Jan 06, 2019, 12:16:12
Nice work! That old XT is getting some love!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 06, 2019, 16:38:48
Nice work! That old XT is getting some love!

Yes definitely! I have done every inch of this bike!
Nearly finished! Parts should arrive tomorrow. Canít wait to get it going.


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Title: Re: 1980 XT500 BUILD
Post by: JustinLonghorn on Jan 07, 2019, 10:23:11
I can dig it.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 13, 2019, 03:38:21
I have a question, i hope someone can help.

There doesnt seem to be any marks on any of these cogs. So while re-installing the clutch basket. how do i know i have the clutch basket cog line up with the correct teeth. i have read the manual but cannot seem to find a clear answer.

I assume the clutch basket must line up with the oil pump cog, the kick starter and the contact breaker cog. All on the correct teeth.
but there are no marks apart from the marks on the contact breaker.

So can anyone help?
Title: Re: 1980 XT500 BUILD
Post by: teazer on Jan 13, 2019, 11:21:00
Crank and breaker shaft are geared together to set ignition timing.  The rest don't matter.  Just fit the clutch basket and keep going.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 13, 2019, 17:45:55
Crank and breaker shaft are geared together to set ignition timing.  The rest don't matter.  Just fit the clutch basket and keep going.
Really?
Ok great thanks for the help. Iíll get onto it!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 15, 2019, 21:56:35
Quick question for everyone!

While lining up the marks on contact breaker shaft. and installing it.

Where does the piston need to be. does it need to be TDC ? because i have noticed it goes around twice, and i dont want my timing to be 180 degrees out!
So do i line up the marks on the "T" mark as per the pic. with piston at the top?

Any help is very much appreciated.

Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 19, 2019, 02:31:46
Yep all good, bike needed to be at TDC on compression stroke.
I put everything back together . and the bike is started first kick!!
Just rode it up and down the street a few times.
Title: Re: 1980 XT500 BUILD
Post by: teledan on Jan 21, 2019, 12:00:11
NICE!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 22, 2019, 04:45:09
Thanks Teledan,
I feel like im only writing to you! haha your the only one that replies. I think the thread has gone a bit flat.
Anyway im going to carry on, perhaps it will help someone some day!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 22, 2019, 04:51:59
The headlight i have been using is good, but it really has been too tight for all the cables and wires, the headlight shell was too wide. So i am going to swap it out for a thinner headlight.
A couple of times the throttle cable especially was pulling when i turned the handle bars, i am really unhappy with everything so squashed. So a new thinner headlight and some cable re routing will be the best option for a smooth turning circle and free up some space.

Dont want any issues while fanging it down the street on one wheel. brrraaaaaaaaabbbb!!!!
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 22, 2019, 04:56:51
Much better, really happy with the way the cables are all organised, it was a bit of trial and error getting the cables all in the right spot. but super happy how clear it is now.
Title: Re: 1980 XT500 BUILD
Post by: pidjones on Jan 22, 2019, 07:17:06
Turning radius and cable interferrence shouldn't matter while on one wheel, but I do like the new bucket. Yes, there are others lurking. Watching. Taking notes.
Title: Re: 1980 XT500 BUILD
Post by: CrabsAndCylinders on Jan 28, 2019, 00:00:36
I'm lurking too, just have nothing of merit to post.  :)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 02:32:57
awesome thanks guys.
everything is working great and super happy with the bike. but im having a wiring issue and its driving me nuts.

ill post something shortly about it.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 16:48:58
Quick electrical question: Iím installing a led rear tail light,
do I need a led light resistor?


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Title: Re: 1980 XT500 BUILD
Post by: Sonreir on Jan 28, 2019, 17:42:50
Not usually. If the tail light was designed to work on a 12V system, they're almost always a straight swap.

Some of them are only a two wire system and require a resistor and some wiring to make them work for both running light and brake light, but that's rare. I've only come across that style a handful of times in the past five years.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 17:57:06
By the way itís a 12v led light and I have done a 12v convention for the lights only.


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Title: Re: 1980 XT500 BUILD
Post by: Sonreir on Jan 28, 2019, 18:00:21
Sounds good to me, then. Hook it up and it should just work.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 18:03:07
Awesome , thankyou so much for the advice!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 18:04:32
I have another quick question.

My headlight is very very low and Dim, but as I give the bike some throttle, the headlight lights up bright.
Do you know why that is.


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Title: Re: 1980 XT500 BUILD
Post by: Sonreir on Jan 28, 2019, 18:15:59
Not uncommon for a lot of dual sports and dirt bikes.

Usually the lighting circuit is run directly from the stator and brightness will increase with engine revs. You can modify it to run from the battery and that will help. I recommend an LED for the headlight as well.
Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jan 28, 2019, 18:56:19
Get you a Trail Tech AC regulator to run your lights through. 

https://www.trailtech.net/7003-ac01
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 28, 2019, 21:26:40
Ok and so what will that do?


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Title: Re: 1980 XT500 BUILD
Post by: irk miller on Jan 29, 2019, 00:51:09
Ok and so what will that do?


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It gives you consistent power to your lights, so no more flickering or dim lights.  I think they make both the adjustable and fixed regulators.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Jan 29, 2019, 01:06:33
Ok, thatís interesting. Thanks for that I will definitely look into it.

I think there is something wrong with my wiring. Because the lights are so dim when the bike is running. They are almost off!

It that what itís supposed to be like?

I bought a bulb 12v headlight because itís the only one I could find that had a slim back to fit all my cables behind the handlebars etc. I had a h4 headlight but the casing of the headlight kept getting in the way of my cables so I had to remove it.


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Title: Re: 1980 XT500 BUILD
Post by: Psycrow on Jan 31, 2019, 08:13:58
Not uncommon for a lot of dual sports and dirt bikes.

Usually the lighting circuit is run directly from the stator and brightness will increase with engine revs. You can modify it to run from the battery and that will help. I recommend an LED for the headlight as well.
Mckay, Sonreir is correct the headlight is AC and runs directly off the stator lighting coil so it is dim at idle and gets brighter with engine revs. If your going to mess with the electrical I would highly recommend you look at the XT forum for relevent posts and check out https://www.rexs-speedshop.com he is the expert on these electrical systems. LED signals and tail lights are useable with his 12v conversion kits but not LED headlights.  They will not like the AC current. Running anything additional off the battery is also problematic on stock stators as they barely make enough current to keep the small batterys charged as it is. Its all the tutorial pages. However If you end up ignoring all that and find a setup that works please post it up... Ive been looking for a headlight upgrade solution that works too ;) good luck

Psy

 

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Title: Re: 1980 XT500 BUILD
Post by: jordandogtown on Jan 31, 2019, 10:09:37
x2 on the trail tech regulator. They know their stuff when it comes to dirtbikes and lights
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Feb 01, 2019, 02:33:38
yes, i will do, thanks for that. I have already purchased a 12v conversation kit from rex's shop.

Waiting for a new break light arrive shortly.

Im very close to finishing. just these last couple of things. and im done!

Thanks for the advice guys. im very appreciative
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Feb 02, 2019, 02:34:59
hey guys!

Does anyone have a theory on this issue im having.
My ignition have 4 positions.

off / daytime running / night time riding (lights) / off

My rear break light works while on daytime riding position. But when i turn the key to night time riding position to use the lights. my break light stops working. turn it back to daytime riding. break light works again.

Also my break and tail light are both turning on at the same time. when break is pressed

i have hooked up everything correct as far as i know. just wondering if anyone has had an issue like this. and perhaps im missing something

 
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Feb 08, 2019, 01:02:11
Ok problem is solved with the brake light,
Turns out the brake light I had was faulty. So I installed a new one. And brake light and tail light are working great !


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 09, 2019, 03:42:02
Sorry to everyone for the long delay.
i have been waiting for parts. But everything is perfect now! sent it off for road worthy today, and passed with flying colours!
The bike is starting first kick! and running perfect. no complaints and loving every second of it.

Does anyone have any thoughts on tank paint options?
Title: Re: 1980 XT500 BUILD
Post by: Brodie on Apr 09, 2019, 06:12:27
Looks great.

As for paint I recon either a metallic gun metal grey or a Slate grey.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 09, 2019, 06:18:05
yeah slate grey would look awesome!

im even starting to think maybe yamaha yellow. with a black yamaha decal.
something like this pick.
Title: Re: 1980 XT500 BUILD
Post by: killerx on Apr 09, 2019, 11:17:25
I like the yellow and black.
I love bright bold colors on bikes.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on Apr 16, 2019, 03:35:37
I like the yellow and black.
I love bright bold colors on bikes.

Hey everyone I donít suppose anyone knows the Yamaha yellow colour code for this yellow paint? I can only assume this is a Yamaha colour.

Any help would be great!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 09, 2019, 05:15:26
Almost finished , just got the tank painted!
Looks awesome.
Title: Re: 1980 XT500 BUILD
Post by: Brodie on May 09, 2019, 05:20:47
Nice, very glossy.

No plans for decals?
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 09, 2019, 05:55:31
yes, just going through some decal ideas at the moment, i want to do original xt500 decals, i think. but i dont want the red to clash with the yellow. so i might leave the red out.
Title: Re: 1980 XT500 BUILD
Post by: stroker crazy on May 09, 2019, 08:57:12
i might leave the red out.

Red can work well with yellow - try a few samples ...

Crazy
Title: Re: 1980 XT500 BUILD
Post by: teledan on May 09, 2019, 11:17:10
I think the black and white speed block pattern looks good on the yellow. I don't think red would look good on the yellow, it might look too much like a hot dog stand. But you never, it might work out.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 09, 2019, 18:36:59
Hahah, a hot dog! Definitely donít want that, I have mocked up a decal I think will work, I wanted to keep the original xt500 decal on the tank. Rather than have a random DT decal on an XT it felt weird. The new decal should arrive soon, I will post as soon as it arrives!
Then the long build journey will be over! Only a few posts left!


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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 14, 2019, 05:35:24
hey guys!

Put the tank on today, and the Decals ,
So what does everyone think of the colour option?
Title: Re: 1980 XT500 BUILD
Post by: Brodie on May 14, 2019, 05:48:12
Looks rad. Might be cool to do some yellow accents on the black guards.
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 14, 2019, 05:59:24
Looks rad. Might be cool to do some yellow accents on the black guards.

Thanks Brodie!!!
Iím done! No more work for me hahah


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Title: Re: 1980 XT500 BUILD
Post by: Mr Bernzo on May 14, 2019, 06:55:29
Very nice! Well done.

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Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 14, 2019, 06:57:10
Very nice! Well done.

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Thanks mate! Will upload some better pics this week!

Just wanted to show the tank with the decal.


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Title: Re: 1980 XT500 BUILD
Post by: stroker crazy on May 14, 2019, 08:45:00
Looks good!

Crazy
Title: Re: 1980 XT500 BUILD
Post by: JustinLonghorn on May 14, 2019, 08:55:12
I can definitely dig it.
Title: Re: 1980 XT500 BUILD
Post by: teledan on May 14, 2019, 11:13:02
Love it! Excellent work!
Title: Re: 1980 XT500 BUILD
Post by: killerx on May 14, 2019, 11:16:53
Very cool!
Some more yellow wouldn't be bad. 8)
Title: Re: 1980 XT500 BUILD
Post by: MCKAY34 on May 15, 2019, 06:32:49
EVERYTHING IS FINISHED AND COMPLETE!!! I WOULD LIKE TO THANK EVERYONE WHO HELPED ME OUT WITH THERE GREAT COMMENTS AND ADVICE THROUGHOUT THIS BUILD! THE BIKE TURNED OUT AWESOME AND IM VERY HAPPY WITH IT, THE SUPPORT FROM EVERYONE HAS BEEN OUTSTANDING! THANKS AGAIN GUYS!!! YOU HAVE ALL BEEN AWESOME I REALLY APPRECIATE  IT!
Title: Re: 1980 XT500 BUILD
Post by: stroker crazy on May 15, 2019, 06:54:19
Magic!

Crazy
Title: Re: 1980 XT500 BUILD
Post by: Jimbonaut on May 15, 2019, 11:32:34
Dude.  You've built yourself an absolute beaut, I love absolutely everything about it.  Now go get your knees in the breeze!
Title: Re: 1980 XT500 BUILD
Post by: killerx on May 15, 2019, 13:32:37
Awesome! Looks like it will be a blast to ride!