DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: SrgtBear on Mar 22, 2010, 13:19:00

Title: '75 Yamaha XS500 Cafe Project - Open Throttle
Post by: SrgtBear on Mar 22, 2010, 13:19:00
Hi Everyone,

I just noticed this DQ Board and I decided I would share what I have been working on in the last year.  I bought a 75 Yamaha XS500B towards the end of the summer this last year.  $200.  Look decent but needed alot of TLC.  Needless to say the bike was sitting and the clutch cable and throttle was broke so I could not fire it up, but the engine did turn.  Since then I took it home a tore it completely apart.  Thus begins the Cafe Racer build.

This last weekend I just got the frame back from powder and started putting all the bits and pieces together that I worked on during the off season.  Engine still not tested....  Looks great on the inside, but still praying for no problems.

Here are some pictures of the build so far.  Let me know whatcha think and I will be glad to keep you posted. See link for HQ Photos and Video

Photos:
http://picasaweb.google.com/Cichocki.T/1975YamahaXS500B?feat=directlink (http://picasaweb.google.com/Cichocki.T/1975YamahaXS500B?feat=directlink)

Video:
1975 Yamaha XS500B Cafe Racer Project (TX500) (http://www.youtube.com/watch?v=_AsSeOdPC5w#)

Snapshot:
(http://lh3.ggpht.com/_9MkPMWmQs4I/S6biGvweL8I/AAAAAAAADrg/Cq8H7WdQ6pY/s720/IMG_1188.JPG)

Thoughts, Suggestions, Comments.

Thanks,
Ted Cichocki
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Big Rich on Mar 22, 2010, 14:39:42
Welcome to the site man. the Yam is looking good so far. I like the red bolts, can't wait to see it come together.

But uh..... what's the story with the Honda?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Mar 22, 2010, 14:54:24
Welcome to the site man. the Yam is looking good so far. I like the red bolts, can't wait to see it come together.

But uh..... what's the story with the Honda?

Oh...what?  That little guy?  :)    It's a 1974 Honda XL125.  Found in almost mint condition buried in one of my neighbors garage.  My father actually spotted it and after a little talk it was his for.. well about $200.  Rebuilt Carbs, cleaned fuel tank and fired right up.  It's an awesome little whip.  It does great on the street and on dirt.  In the shed there is also a 1973 Yamaha AT1 Enduro, 2 stroke.  Restored but not original.

Thanks for the comments! 
Title: 1975 Yamaha XS500B Cafe Project (TX500) - Update - Polishing Forks
Post by: SrgtBear on Apr 05, 2010, 01:27:47
Update - Polished Forks are Finish...  After thought, don't want to do this again anytime soon.

When I decided I wanted to hand polish my forks I never would of thought it would take so much work.  I spent about a week just on one tube alone.  It's a messy pain staking process.  However, once I got the hang of it the second one was done in no time and I was so glad i didn't throw in the towel and paint them.  I swear I was that close.  Results,  "ohhhh man look at those shiny puppies.  I love them!"

Here are some tips that I learned that will save you some time.  First, buy / have a table top bench grinder with min two buffing wheels.  Makes sure you get the correct compounds.  I bought a kit from Harbor Freight that came with an assortment of buffing bits for a drill and 3 compounds, black (rough), red (medium), white(superfine).  Use the black stuff first and get the first layer off the metal.  Follow by using drill bit attachments to get the hard to reach areas.  Apply pressure!   Switch to a new wheel and use the red stuff to get it real glassy, then finish it off with white compound.  Wipe off with a rag periodically to check results.  Be sure to wipe off completely before switching to next compound.

When your done.  Clean it off good.  I found that degreaser and a paint brush worked the best.  Follow by soap and water.  Dry immediately so you don't give it time to rust.  Finally, Get some Mother's Mag and Aluminum Polish from Pep Boys.  Follow Directions.  Then Wax the polish areas to protect them.  Wipe wax off good and Wahla!  Those puppies should shine.   :)
(http://lh3.ggpht.com/_9MkPMWmQs4I/S7lhdYOMxBI/AAAAAAAADyI/F52SjVgUmK0/s512/IMG_1225.JPG)(http://lh5.ggpht.com/_9MkPMWmQs4I/S7lhfXuSbJI/AAAAAAAADyQ/m2d6WnclXM0/s512/IMG_1226.JPG)

-=Ted=-
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Rocan on Apr 05, 2010, 02:21:43
make your own polish. its cheaper and way better then store stuff.

my final hand polish is as follows...

3/10 final rouge (white), 2/10 medium rouge (brown or red), 5/10 mineral spirits (paint thinner). boil them OUTSIDE under SAFE conditions until you get a nice mixture. crush the rouge first to speed things up. paint thinner is VERY flammable; excercize caution.

my sealer polish is as follows... 3/10 white rouge, 3/10 caranuba or PURE beeswax, 4/10 mineral spirits.


i agree. polishing is a pain in the ass. im a bit psycho... i got three or four minor scratches in my fork leg and its been on my mind for the past 5 days. im going to tear the fork down again and go back to black rouge to get them out. fml.

those look good none the less.
Title: Update #2 - Wheels, Grease, and XS Completely Naked
Post by: SrgtBear on Apr 15, 2010, 01:43:42
Had some time to snap some photos today.  Finally got the front wheel finished.  Greased up and lubed both axles and slapped them on there.  Installed some headlight ears from MikesXS.  Btw, they weren't a perfect fit right away.  Had to bend them so they would latch better.  If you look below the ears you'll see a chrome cover that hides the bottom tree and brake switch.  Normally the old headlight ears would hold this down this cover...  So with a little thought I pulled out an extra set of fork seals i didn't use and they worked like a champ keeping the cover down nice and tight.

Finally, I also attached the kick stand with a little red flair.  P.S.  This kickstand sucks ass!!!  If someone was to nudge the bike forward by accident it would flip right up and fall over.  Can't wait to get the center stand on.

(http://lh6.ggpht.com/_9MkPMWmQs4I/S8aU9SBO3KI/AAAAAAAAD0w/5bJ6jMNGXMA/s640/IMG_1231.JPG)(http://lh5.ggpht.com/_9MkPMWmQs4I/S8aU_pbgRSI/AAAAAAAAD04/GPeGg1aYvyc/s512/IMG_1233.JPG)(http://lh4.ggpht.com/_9MkPMWmQs4I/S8aVBvbXz3I/AAAAAAAAD08/4qSmOmqJe0g/s512/IMG_1234.JPG)(http://lh6.ggpht.com/_9MkPMWmQs4I/S8aVDvERkWI/AAAAAAAAD1E/IqAL4tP6FFw/s640/IMG_1235.JPG)(http://lh5.ggpht.com/_9MkPMWmQs4I/S8aVH5MfhdI/AAAAAAAAD1M/uqJnfIF4fK8/s512/IMG_1237.JPG)

All HQ Photo can be found at link in first post.

-Ted
Title: Re: Update #2 - Wheels, Grease, and XS Completely Naked
Post by: Big Rich on Apr 15, 2010, 11:45:31
P.S.  This kickstand sucks ass!!!  If someone was to nudge the bike forward by accident it would flip right up and fall over. 

if you take the stand back off, you can grind (sparingly) the front / bottom edge of the stopper so it swings forward a little more. Just don't take off too much or else the bike will lean too far to the left.

Looking good so far BTW!
Title: Re: 1975 Yamaha XS500B Cafe Project - Engine Update
Post by: SrgtBear on May 31, 2010, 18:26:09
Well it's been awhile since I've updated my thread.  Since last post its been all engine work.  I was dreading doing it because of the sheer weight of this beast and how grungy it looked but it's all worth it in the end.

Engine was blasted, degreased, blasted some more, made some gaskets for both oil plugs and finally got it ready for paint.

The main body has a wrinkle finish.  Used VHT Wrinkle plus.  Spray vertical, spray horizontal, spray diagonal.  Much fun...   Finish looked like crap when wet but when it dried it looked fantastic!  Really like the way it turned out.

Engine 50% complete.  Chrome valve and side covers next.

(http://lh3.ggpht.com/_9MkPMWmQs4I/S_FJZxw6L1I/AAAAAAAAD6Y/-qEKCLFvtdI/s800/IMG_1248.JPG)(http://lh6.ggpht.com/_9MkPMWmQs4I/S_FJb_bZsVI/AAAAAAAAD6c/voPX1mOlBEU/s800/IMG_1260.JPG)
(http://lh4.ggpht.com/_9MkPMWmQs4I/TAQjhZcmgzI/AAAAAAAAD_4/12vyM1FEVc4/s800/IMG_4263.jpg)(http://lh5.ggpht.com/_9MkPMWmQs4I/TAQjev5K4hI/AAAAAAAAD_w/_5kKXrApFco/s640/IMG_4264.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: n0regret5 on May 31, 2010, 19:52:24
FYI the fork lowers are aluminium, not steel.. :D looks bitchin! can't wait to see this thing coming together, love those TX's
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 01, 2010, 02:11:49
FYI the fork lowers are aluminium, not steel.. :D looks bitchin! can't wait to see this thing coming together, love those TX's

Lol. Yes they are.  It's hard to make a video and get it all right the first time.

Thanks for the compliment.  :D
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: n0regret5 on Jun 02, 2010, 05:04:17
all good. moar work! MOAR PICS!!!!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: bikeboy on Jun 02, 2010, 07:01:40
Looks good so far. Will be watching this come together for sure  ;)

cheers
ian
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 13, 2010, 22:36:26
First full inspection of the engine. Real clean. Rebuild Contact Points and adjusted Tappet/Lifter valve clearances. Covers sent out for chrome.

(http://lh4.ggpht.com/_9MkPMWmQs4I/TBWCMZlRjlI/AAAAAAAAECA/BKgJX8UNo-Y/IMG_1281.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TBWCQHVtzEI/AAAAAAAAECI/8DtxEhp8cVI/IMG_1283.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TBWCTKWZ_QI/AAAAAAAAECM/jAUTm4G22Gg/IMG_1285.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Big Rich on Jun 14, 2010, 03:42:28
Chromed covers, huh? That will be nice to see. Glad the motor's treatin ya well.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Polished Carbs, Pod Filters
Post by: SrgtBear on Jun 28, 2010, 10:04:39
Finally got the engine in the frame.  Polished up the carb caps and float bowls.  Pod filters are from www.hvccycle.com (http://www.hvccycle.com) and look freaken sweet.  I used Joe's (JRK) recommendation of using copper pipe tubing insulation when installing the engine so nothing got dinged up.  Still waiting for chrome pieces to come back.

Enjoy!
(http://lh6.ggpht.com/_9MkPMWmQs4I/TCgAPL3F3mI/AAAAAAAAED8/QGXdfNCCno8/s640/IMG_1301.JPG)
(http://lh4.ggpht.com/_9MkPMWmQs4I/TCgANCEL7FI/AAAAAAAAED0/qHgW_A1wac4/s640/IMG_1300.JPG)
(http://lh6.ggpht.com/_9MkPMWmQs4I/TCgASFsRHYI/AAAAAAAAEEA/unjBwBkVIaE/s512/IMG_1302.JPG)
(http://lh6.ggpht.com/_9MkPMWmQs4I/TCgAd3FGANI/AAAAAAAAEEU/tvuSWWaiH5Q/IMG_1308.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jun 28, 2010, 16:55:14
You may want to consider adding an oil cooler and/or perhaps a small fan blowing directly on the head.
The 500s have a tendency to crack the heads so anything will help.
Looks like a nice job thus far, I can't wait to see how the chromed bits look with the wrinkle....should be gorgeous!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 28, 2010, 17:20:21
You may want to consider adding an oil cooler and/or perhaps a small fan blowing directly on the head.
The 500s have a tendency to crack the heads so anything will help.
Looks like a nice job thus far, I can't wait to see how the chromed bits look with the wrinkle....should be gorgeous!

Thanks, yeah joe did an awesome job with his tx500 oil cooler.  But, Im not sure i have the knowledge or know how to pull it off.  I have the air scoop for the bike and after reading a bunch of stuff it looks like the real issue is to make sure the tappets clearances are adjusted right or it will get hot and overheat...and maybe crack.  The engine has about 10,000 miles on it and still looks beautiful inside.  Pulled off the spark plugs and cylinders look super clean and intact.  Whoever had the bike before looked like they maintained it well.  We will see... 

If you have any knowledge on how to add a oil cooler to this bike by all means share.   :)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jun 28, 2010, 18:20:20
Off the top of my head..no I don't. I think we had one in the hsop here for a grand total of 3 days....not much time for exploration. Joe however should be able to point you in the right direction. If it's fitment ie; tapping for oil lines and such that you're not comfortable with I'd be happy to help.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Maritime on Jun 28, 2010, 19:28:06
Joe used an adapter on the oil filter to put his cooler on, there are pics on his build.  Looks great so far, hate for you to have a cracked head after all of this.

Cheers,

maritime
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 28, 2010, 19:44:41
Off the top of my head..no I don't. I think we had one in the hsop here for a grand total of 3 days....not much time for exploration. Joe however should be able to point you in the right direction. If it's fitment ie; tapping for oil lines and such that you're not comfortable with I'd be happy to help.

Joe used an adapter on the oil filter to put his cooler on, there are pics on his build.  Looks great so far, hate for you to have a cracked head after all of this.

Cheers,

maritime

I know!  I'd hate for that to happen too.  Let me ask you guys this then,  what do you think about this Billet Oil Cooler?  Fuctional or a complete piece of crap?  The idea of heat sinks works on computers so why not here on my bike....?

http://cgi.ebay.com/ebaymotors/Billet-Oil-Cooler-Honda-Goldwing-Kawasaki-Yamaha-Metric-/390212996731?cmd=ViewItem&pt=Motorcycles_Parts_Accessories&hash=item5ada81ce7b (http://cgi.ebay.com/ebaymotors/Billet-Oil-Cooler-Honda-Goldwing-Kawasaki-Yamaha-Metric-/390212996731?cmd=ViewItem&pt=Motorcycles_Parts_Accessories&hash=item5ada81ce7b)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jun 28, 2010, 20:12:30
You might see a couple degrees but more than likely not much of an improvement there.

Your best bet is to plumb one into the oil pump. A filter adapter is the way to go for simplicity.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 28, 2010, 20:20:59
You might see a couple degrees but more than likely not much of an improvement there.

Your best bet is to plumb one into the oil pump. A filter adapter is the way to go for simplicity.

I was looking at that filter adapter.  I gotta figure out how it fits.  It requires 1 inch of clearance and that's crazy with how tightly packed the covers are to the filter.  Steve and his clean TX500 mentioned something about running bigger jets because the stock ones run to lean.  That might be part of the solution.  Well I'll keep ya posted.   http://www.dotheton.com/forum/index.php?topic=5959.140 (http://www.dotheton.com/forum/index.php?topic=5959.140)

Thanks Swag
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Triple on Jun 29, 2010, 22:17:46
Nice work mate, I used the VHT wrinkle black paint on my XS850 head and barrels and polished the outer lip. Looks sweet.
Also if you're worried about the bike rolling off the center stand, just leave the transmission in 1st gear and the rear wheel will stop it!


Cheers
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 30, 2010, 09:15:51
Nice work mate, I used the VHT wrinkle black paint on my XS850 head and barrels and polished the outer lip. Looks sweet.
Also if you're worried about the bike rolling off the center stand, just leave the transmission in 1st gear and the rear wheel will stop it!


Cheers

Good idea!  Why didn't I think of that, duh... VHT wrinkle does look sweet.  I am really happy with it.  Thanks for the props.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jun 30, 2010, 14:20:51
how did i miss this sucker! nice work man!!!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jun 30, 2010, 15:01:24
how did i miss this sucker! nice work man!!!

Thanks Joe.  I got a lot of good ideas from your build including painting the starter cover which you probably noticed.  I also bought a braided chrome wire cover kit too.  I'm thinking about putting knee cut outs in the tank and/or stretching it.  I have no experience in this kinda stuff but my father is pretty crafty so we'll see.  Then I would finish up with Carpy's cafe seat and a red and black or silver paint scheme.  Gotta measure first. 

Hopefully something like this design and scheme for the tank and seat but in red and black or silver stripes.
(http://www.cb750cafe.com/upload/library/179a.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 08, 2010, 14:14:06
So my cover are on their way back from Chrome.  Next Step will be to put some motor oil in it.  The manual says 20w-40, but from my understanding Yamaha is the only person who sells this.  I want to upgrade to synthetic because it can handle the higher temperatures.  I found a few places where people are using SAE 10W-40 Synthetic Motorcycle Oil for their bikes.  It has a wet clutch so obviously this is also a concern.

Will 10w-40 Synthetic work on this bike?  recommendations? Thanks.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 08, 2010, 14:14:53
i use rotella 20w 50 in mine runs great
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 08, 2010, 14:19:12
i use rotella 20w 50 in mine runs great

awesome!  thanks for the quick response joe.  Where did you buy your oil?  Motorcycle shops have this stuff available or internet purchase?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: beachcomber on Jul 08, 2010, 18:35:37
Nice work Bear - an inspiration for my own build . A sixties style Cafe Racer and a Flat Tracker [ bought 2 bikes for the price of 1 ! ]

Swagger - can you tip me in the direction of the oil cooler thread? Can't find it - ta.

What about an adaptor with remote oil filter as with car engines?
I'm just bidding on a pair of Borrani rims [ e-bay] - fingers crossed.

BTW - Rotella oil - here in the UK it's readilly available in commercial vehicle and farm outlets - and half the price of auto / bike oils !

We recently found a wrinkle paint that is much more consistent than VHT - it's not actually used for automotive purposes, but we have been using it now for 3 years. Much simpler to apply than VHT.

The guy only did Black, but we recently persuaded him to produce Red, Gold and aluminum.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 12, 2010, 14:17:50
Worked on the controls this weekend.  I didn't want to buy new ones but the old switches looked like crap.  So I taped up gold emblems and painted over it.  Then I lost the high beam, "Hi / Lo" knob so I used a rivet instead.  Cut it down glued it in and wahla!  This image doesn't do justice but it looks really clean granted the paint job on the control switch isn't the best, but it is still way better than before.

(http://lh4.ggpht.com/_9MkPMWmQs4I/TDtKas-Cd6I/AAAAAAAAEJ0/zA20pshW_-E/s640/IMG_1408.JPG)

Finally, I was debating sanding down the engine fins for awhile so I eventually said screw it and went for it.  I think it makes it more eye catching now.

(http://lh3.ggpht.com/_9MkPMWmQs4I/TDtLAADXXxI/AAAAAAAAEJ8/Ef0sQlpJlQY/s800/IMG_1395.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: kingofthenuggets on Jul 12, 2010, 14:39:41
Hey whatever works!!  Pictures do the same to my bike too, I think it looks really awesome then snap a pic and it's like "this looks kinda gay ..."  I am sure it will do ... Are you going to do all the fins or just the middle?  I think it looks pretty rad just like that.  Good work!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 12, 2010, 14:41:11
fins look good!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: beachcomber on Jul 12, 2010, 17:35:41
Agree re: taking loads of pix for referrence / eyeballing.

AND downloading other people's pix works when you're toying with an idea!

I had been toying with the idea of highlighting the fins on the barrels and heads - looks good !

I collect my 2 project bikes tomorrow - can't wait to get stuck in.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 12, 2010, 21:36:47
Hey whatever works!!  Pictures do the same to my bike too, I think it looks really awesome then snap a pic and it's like "this looks kinda gay ..."  I am sure it will do ... Are you going to do all the fins or just the middle?  I think it looks pretty rad just like that.  Good work!

fins look good!

yeah im going to stick with just the middle fins.  it def looks cherry.  thanks btw!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: mdfergus on Jul 16, 2010, 15:02:43
Wow the sanded fins really look good, that'll go great with the chrome covers
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 16, 2010, 16:05:34
Chrome covers came in.  I haven't seen them yet but my pops said they look "Magical".

Will take pictures this weekend.  Bling Bling.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 16, 2010, 17:11:18
stoked to see em man!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 18, 2010, 23:17:59
Fresh Chrome!!!  Check out these bad boys.  I can't believe their the same parts that I sent out.

Before:
(http://lh3.ggpht.com/_9MkPMWmQs4I/TBWCWc0gWDI/AAAAAAAAECU/pu4mQybssRg/IMG_1288.JPG)

After:
(http://lh3.ggpht.com/_9MkPMWmQs4I/TEOyM24ob8I/AAAAAAAAELQ/4fcMU2Nq5Nc/IMG_1415.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TEOyKnydgaI/AAAAAAAAELM/x8vnh1B_m3A/IMG_1417.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 18, 2010, 23:20:30
My little fire engine.  Looks like one, doesn't it?
(http://lh3.ggpht.com/_9MkPMWmQs4I/TEOyTemuY1I/AAAAAAAAELc/XLYC3ZHSZ6A/IMG_1451.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TEOyWm15lcI/AAAAAAAAELk/NkIfIXWOGks/IMG_1448.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: travstoll on Jul 18, 2010, 23:25:48
excellent!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Big Rich on Jul 19, 2010, 00:30:35
Wow...... just wow.

I'm not normally a big fan of chrome (I'm cheap and like polished aluminum  :D), but that looks freaking........ wow
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 12:15:22
wow man that looks fantastic!!!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 19, 2010, 12:38:00
Thanks.  The engine is clearly the best looking part of the bike.  Now I really gotta do a nice job on the top end in order to balance things out.

I got some photoshop mach-ups i've been working on.  I'll put them up later tonight.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 12:43:01
what you going to do for pipes and intake? my V stacks are gone! could not get the bike running we are now going to up the pilot and go though the jets again trying to get it right. tuning this bike is a BEAR!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: kingofthenuggets on Jul 19, 2010, 12:52:22
Damn ... thanks for making me feel bad about not showing my bike the same love.  Looks freakin' swank ... I hear fire engine sirens!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 19, 2010, 12:55:47
what you going to do for pipes and intake? my V stacks are gone! could not get the bike running we are now going to up the pilot and go though the jets again trying to get it right. tuning this bike is a BEAR!

lovely...   I have pod filters for the intake.  I was original thinking of using some universal mufflers.  A Reverse Cone Megaphone Muffler or the Commando Style Megaphone.  On the other hand I really like the strait headers look or slash cut pipes, but it sounds like this bike really needs some back pressure.

Reverse Cone:
(http://www.mikesxs.net/parts/img250/07-0112.jpg)

Commando Style Megaphone:
(http://www.mikesxs.net/parts/img250/07-0065.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Big Rich on Jul 19, 2010, 13:22:27
JCWhitney sells some reverse megaphones that the end cap unbolts. That way you can pull the baffle out for "tuning"
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 13:36:33
my pipes have a full baffle in them and still are a bear... ill let you know what we end up doing on the tune. just sucks... the bike has been done over  year,  it is now in the hands of the 2nd tuner including myself, the carbs are spotless, have 5 up and 5 down jets from stock, vavles are set (very important on this bike) carbs are synced, timing is on... and just runs like crap, sticks high idol around 7 or 8g's dies out, just a bitch
problem is the tuner has had the bike for around 4 months and the swing arm is now rusted to hell, all the polishing work i did is getting worse and worse... just sucks... he is working his tail off (forum member as well) just be bike is not workign with us... hope that when we get rid of the V stacks it does it!
took her for a few mile run yesterday... now back to the begining... ha ha ha ooh well when it is done i can bring him another goldwing to dial in as i start on the next build

Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jul 19, 2010, 18:18:34
It's your CV carbs Joe...I'm almost certain of it.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 18:20:50
what you think i can do about it? you think that gettin rid of the V stacks will work?

here is a shot of her out yesterday with the wife on her fighter... made it a few miles!
(http://i32.tinypic.com/v79qv6.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 19, 2010, 18:34:45
Do you only start having problems when the engine gets fully warmed up?

Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 18:36:23
nope cold, warm, midway... just all though the range, tried over 5 diff jets, i refuse to change my exhaust (it sounds wicked and i got to much time into making it) but i will put on the stock air box if i have to! this thing is driving me nuts that it looks so sick and i can not ride it! just blows!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jul 19, 2010, 18:43:33
Srgt: Meant to say before: That plating looks outstanding, really takes the engine u pa notch or two!

Joe: Best thing you could do.....
1) add some length to the exhaust. It'll help, trust me.....plus by adding some length you can probably get rid of some/all of your back pressure by removing the lolipop.

2a) VM30 carbs. You cna get'm pretty cheap and there's enough info out there that getting them jetted is pretty easy. Hell, grab yourself a couple dial-a-jets and have external control! This really is the best long term solution, the vacuum carbs just suck in an open flowing system

2b) Put your stock airbox back on. I know it sucks but htis will at least allow the carbs to work as designed. There will be enough restriction on the inlet to allow the vacuum from the engine to properly operate the slide. 

2c) you can try drilling out the little 'vent' hole in the slide to help it work a little better with less vacuum. The old Dynojet kits used to include the drillbit for doing that....

But really, the VMs are the ticket mate!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 18:55:48
man i am sorry for the thread jack....

you thinking these would do it?

http://cgi.ebay.com/ebaymotors/Mikuni-Carbs-VM30-Tricked-Out-Yamaha-RD400-_W0QQcmdZViewItemQQhashZitem3a5ce10ddeQQitemZ250666356190QQptZMotorcyclesQ5fPartsQ5fAccessories (http://cgi.ebay.com/ebaymotors/Mikuni-Carbs-VM30-Tricked-Out-Yamaha-RD400-_W0QQcmdZViewItemQQhashZitem3a5ce10ddeQQitemZ250666356190QQptZMotorcyclesQ5fPartsQ5fAccessories)


i am just worried about the stock airbox... mainly cause i have no fn clue where it is!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 19, 2010, 18:58:05
haha. i don't mind at all.  This is all useful information that I will need once I get to tuning.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jul 19, 2010, 19:07:30
Srgt: You're a good sport!

Those can be made to work though they are set up for a 2-stroke but I believe all you need to do is un-shroud the needle seat. PJ will be able to tell you exactly, I haven't done it but I read something and remember him mentioning it.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 19:09:19
i will first try  the pods, i got so much work into these carbs i would be sick if i could not use them.  keep trying over and over right! ha ha ha what is the dial thing you are talking about?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jul 19, 2010, 19:20:34
Ok, option 3)
make a piece like your exh. lolipop that fits inside the neck of the carb on the inlet side that'll help create some vacuum.

http://www.thunderproducts.com/dial_a_jet.htm (http://www.thunderproducts.com/dial_a_jet.htm)
nifty!!!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 19, 2010, 19:22:24
Here is a whole thread on pod filters:
http://pnwriders.com/mechanical-technical/127667-pod-filters.html (http://pnwriders.com/mechanical-technical/127667-pod-filters.html)

According to these guys looks like the stock airbox is the way to go if you don't want power band problems.  Personally I think they are a heap of tin when it comes to the cosmetics.  Keep me posted if you fix it and dial it in.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 19:23:45
on my pipes i have torque cones in there

(http://i40.tinypic.com/2q0rsc6.jpg)

then baffels, the pipe is expanded to fit the baffle and work. so i have the pressure i need
(http://i39.tinypic.com/2j2jevb.jpg)

(http://i44.tinypic.com/2960lrq.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: Swagger on Jul 19, 2010, 20:14:47
Yup, if you're dead-set on running CV carbs then you really do need the stock airbox. You can tinker with them and get them to run ok but only ok.

If you swap to mechanical slide carbs like the VM Mikunis, and FRS series etc.....then you can easily tune for pods and/or velocity stacks.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: JRK5892 on Jul 19, 2010, 20:20:17
ahhh looks like i need to look for some carbs! i cut all my stock mounts off for the air box so that is a no go... we are going to try with the pods and take it from there. sucks i want to ride this sucker and it looks awesome but has never really run on point!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Mach-Ups
Post by: SrgtBear on Jul 19, 2010, 22:28:01
Okay now I am really going to need everyone's opinion on this.  I got two mach ups going in photoshop. red/black, red/silver.  I hate the side cover but it is needed to hide the junk.  Oh I should probably mention the top view will include a racing strip or two that match.

What color scheme woos you? and... is there anything missing you would suggest...for example the side cover, which i think is kinda dull right now.

The second image has the reverse cone exhaust I was thinking about.  Like, dislike?

Red/Black:
(http://lh6.ggpht.com/_9MkPMWmQs4I/TET5hYyg9UI/AAAAAAAAEMc/E7IHtes3GQI/s640/MACK-UP-BLACK.jpg)

Red/Silver
(http://lh6.ggpht.com/_9MkPMWmQs4I/TET5idcMNQI/AAAAAAAAEMg/IFga4m6ANLo/s640/MACK-UP-SILVER.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: beachcomber on Jul 20, 2010, 06:12:18
Bear, that bikes looking awesome - credit to ya.

Red and White gets my nod [ Off White / Old English White / Cream ???]

BTW - you could always use an oval race plate on the side panel - or make something up?

This is the second bike I bought last week - as you can see, the PO had already started to go down the Flat Tracker route.

(http://)(http://i751.photobucket.com/albums/xx155/vonheyda/Bikes/Bwfh1QB2kKGrHqIOKjwEvoNJi1bJBMKjBIL.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Thoughts, Comments, Suggestions
Post by: SrgtBear on Jul 20, 2010, 23:31:15
I found a picture of this guy's 76 Yamaha XS500 and I had to share. 

Just remember, when your XS gives you problems don't worry, because you could be riding this.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TEZbp2CMvAI/AAAAAAAAEM8/FqWCyUoOAec/wowxs500.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: JRK5892 on Jul 21, 2010, 11:17:39
i like hte red and black
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: beachcomber on Jul 23, 2010, 05:32:43
My new project shown above is on pods and shortie meggas and runs OK. It's been stood for a year, so could benefit from stripping and cleaning the carbs no doubt.
However, I don't poarticularly like the look of the CD carbs. and was looking at alternatives, Mikuni, Amal, Dellorto.
Does anyone have experience with such a swap?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: twinrider on Jul 30, 2010, 15:59:22
great built on the way! I like the way you did the engine, super clean and that extra chrome bling make some accents on bike as a whole.

I'd do the black and red as well, as it will compliment the black hubs... 
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: SrgtBear on Jul 30, 2010, 16:03:20
great built on the way! I like the way you did the engine, super clean and that extra chrome bling make some accents on bike as a whole.

I'd do the black and red as well, as it will compliment the black hubs... 

Thanks, the paint has been such a hard decision.  I agree on the black complimenting the hubs, but I had my eyes set on one of Carpy paint scheme for the longest times.  Here's the pic below.  My picture drawing didn't do justice.  I am unoriginal by stealing this but whatever.  What do you think about this paint job?

(http://www.cb750cafe.com/upload/library/4.jpg)

Still red and black?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: valvesprung on Aug 01, 2010, 01:10:45
Wow engine looks amazing man. I was going to say Red/Silver before the pic, but DEFINITELY after. That looks amazing.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: twinrider on Aug 01, 2010, 17:35:47
well, I have to say that Candy red/silver metallic combo looks awesome!

But you really have to go with the candy red I think and not a simple solid red, you need the deep shine of the candy with the silver!
dont know much about car paint, but it may very well be the same silver used as a basecoat and simply masked and shot over for candy effect...
would be a lot faster to spray for you!

Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: SrgtBear on Aug 01, 2010, 20:37:52
yeah.  def going to get it professionally done.  I want it to look immaculate!

And if the wheels don't match I'll just redo them after.  Can't redo chrome. :-O
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Top End Work
Post by: SrgtBear on Aug 09, 2010, 05:52:34
Hey, just a quick update.  Lots of top end work this last weekend and lots of small parts.  Headlight, signals, gauges, switches, ignition coils, wire harness, carb seals, rebuild caliper and bleed brake.  Wahoo I now have a functioning brake.  Btw, the wiring harness still looks like spaghetti.  That will keep me busy next weekend.

Anyways here is some pictures.  Ignore the beat up tank.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TF9nB1ILPzI/AAAAAAAAEN4/YR1I522KNTs/IMG_1627.JPG)
(http://lh5.ggpht.com/_9MkPMWmQs4I/TF9nEHgxx2I/AAAAAAAAEOA/HlgHKrO8yDY/IMG_1628.JPG)
(http://lh6.ggpht.com/_9MkPMWmQs4I/TF9nGcdt5aI/AAAAAAAAEOE/uu4wVm2f5eg/IMG_1629.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/9 - Quick Update
Post by: Big Rich on Aug 09, 2010, 06:09:09
Looks good man! It's cool how you can tell what you have and haven't worked on yet.

Is that front tire mounted backwards?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/9 - Quick Update
Post by: SrgtBear on Aug 09, 2010, 10:31:42
Looks good man! It's cool how you can tell what you have and haven't worked on yet.

Is that front tire mounted backwards?

haha. thanks.  yea that front time messes with your head.  It apparently mounted correctly but when i first got it i had to check.  And the arrow on the side points the right directions.  It's that stupid "V" tred.  Looks correct against pavement and incorrect when it's staring you in the face.

I bought the bike with some semi fresh tires on it.  Could be incorrect but ehh not a big deal as long as it functions properly.  I'll just be that guy who is different. lol
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/9 - Quick Update
Post by: JRK5892 on Aug 09, 2010, 12:23:09
i thnk we have the same tires on our scoots mine look just the same!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/9 - Quick Update
Post by: SrgtBear on Aug 09, 2010, 12:29:12
i thnk we have the same tires on our scoots mine look just the same!

lol.  i think our bikes are gonna end up looking the same too.  Quick question, how hard was it to install the eye lid on your headlight.  Did you get it off ebay and how did it fit?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/9 - Quick Update
Post by: JRK5892 on Aug 09, 2010, 12:34:45
it was a snap! just tear out the lamp and it goes on the trim ring... i think it was sent to me from a memeber on here if i can recall
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500)
Post by: SrgtBear on Aug 15, 2010, 23:19:46
No new pictures, but I got 98% of my electrical components hooked up.  Lots of soldering my MikesXS gauges to the existing wire harness.  Lots of ridiculous lights on the old dash panel.  For example, a 4 different back lights, a brake light ( like i need to see when im hitting the brake..like i didn't know), also there was a brake lining light.  I was very impressed that a 1975 motorcycle even had such a warning light for the rear drum, but the new tach and speedo didn't have a light for it so i let them go.

After hooking everything I discovered two problems, 1 is fixable, the other isn't.

The major problem was my starting motor.  It spun but didn't sound pretty.  It didn't engage the engine which make me believe it needs lubrication on the internal gears.. or the starting motor gears are grinded down.  I checked the engine sprocket and chain and they were in good shape.  Will take a look at it next week.

The second problem is bearable but kinda annoying.  On of my MikesXS gauges one is brighter then the other.  Voltage is the same on both.  Gauges are same manufacture.  Tach light is brighter cause it only has 1 light in the housing.  Speedo has tons plus there is a mileage and trip meter which i believe are the guilty suspects for why its dimmer.  I think they are just in the way of the back lighting.

Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 16, 2010, 12:07:24
Here is some pictures of my gauge's back lighting issue.  There is only one power source from the main harness.  Then the power branches off to the various back lights.  All are 12volts in the wiring diagram.  I don't think changing the stem off the main source will differ since all the new back lights are LED.

Tach back light is washed out but not that bright in person.  Second picture is in pitch black.  Makes it look worse than it actually is.  It's still noticeable though.
(http://lh5.ggpht.com/_9MkPMWmQs4I/TGlSy9gcwaI/AAAAAAAAEPg/7i3WQf8Y1Cw/s800/IMG_1645.jpg)
(http://lh4.ggpht.com/_9MkPMWmQs4I/TGlSzcIlhgI/AAAAAAAAEPk/3_UD8hd7NBM/s800/IMG_1646.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: Tim on Aug 16, 2010, 12:10:09
Probably just different lights / translucency of the faces in the two gauges.  My gauge backlights burned out a while ago (not even running the tach light).  I don't miss them.  Hardly ever look at the gauges anyhow.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: JRK5892 on Aug 16, 2010, 12:11:52
mine burnt out almost right away as well, replaced them and now they are good to go
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 16, 2010, 12:12:46
Probably just different lights / translucency of the faces in the two gauges.  My gauge backlights burned out a while ago (not even running the tach light).  I don't miss them.  Hardly ever look at the gauges anyhow.

Yeah, I figured I couldn't do much.  I'll just live with them.  Not stressed about it.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: JRK5892 on Aug 16, 2010, 12:15:19
you can also add a resister on the power line, that would work to dim it down a bit
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: Swagger on Aug 16, 2010, 17:36:11
To work from Joe's idea, since you'd need to rewire for your resistor (a big fat one), why not convert them to LEDs? They'll draw far less current allowing your to add a couple $2 radioshack 0/5kohm potentiometers to adjust each gage's backlite to your best setting.
Just a thought....
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 16, 2010, 17:40:41
To work from Joe's idea, since you'd need to rewire for your resistor (a big fat one), why not convert them to LEDs? They'll draw far less current allowing your to add a couple $2 radioshack 0/5kohm potentiometers to adjust each gage's backlite to your best setting.
Just a thought....

I think they are already led back lights.  Plus I can't open the aftermarket gauges.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: Swagger on Aug 16, 2010, 18:26:19
You have no access to the internal bulbs....at all? Sheesh, I guess I'll pass on them.....was looking at adding them to a quick turn bike....
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: JRK5892 on Aug 16, 2010, 18:29:17
how can you put togther something that does not come apart
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: Swagger on Aug 16, 2010, 18:32:47
I'd imagine there's a way, but perhaps not simply. It may be like CB gauges where you have to cut the outer trim ring to access the innards.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 16, 2010, 18:39:32
I'd imagine there's a way, but perhaps not simply. It may be like CB gauges where you have to cut the outer trim ring to access the innards.

im pretty sure that's how these are.  My yamy stock gauges are the same.  No access unless you wanna ruin the trim.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: Swagger on Aug 16, 2010, 19:07:25
No worries there. A dremel with a red cut-off wheel makes a 1/16" or less slice.
When you're ready, reposition the slice at the bottom of the gauge (or whatever is the most obscured) and epoxy it back in place.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: t71ford on Aug 18, 2010, 21:30:36
Hey man, I just got your PM. you have one back!

Nice bike, BTW!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: JRK5892 on Aug 23, 2010, 12:15:22
hey bud do you know what MM the carbs are? i forgot to measure this weekend, and i wanted to order some pod filters for mine, i am giving up on the V stacks! about to give up on these shitty carbs as well!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 25, 2010, 15:06:14
hey bud do you know what MM the carbs are? i forgot to measure this weekend, and i wanted to order some pod filters for mine, i am giving up on the V stacks! about to give up on these shitty carbs as well!

hey joe.  sorry for the late post.  been on vacation.  I bought my pod filters of HVC Cycle.  52mm according to their website and they fit pretty good.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/15 Electrical Stage
Post by: SrgtBear on Aug 25, 2010, 15:15:49
Starter, rotor weights and springs.

So I finally had a chance to analyze the problem with my starter.  The starter motor, shaft, sprocket, and chain are fine.  I actually noticed that the alternator rotor has some type of roller weights that engage the engine when the electric start was triggered.  After further disassembly I noticed that the bottom bell that holds the springs and weights was heavily scored from the friction of the weights.

I don't know if this was causing my problem of the rotor not fulling engaging and sounding like a ratchet that wasn't working right but I order a new rotor anyways that will have smooth surfaces for the weight and springs to operate.

Has anyone ever had any trouble or experience with the starting chain and weights or pins in the bottom of the alternator rotor?

See #9,#10,#11, and #12.
(http://webservices.motorsportdealers.com/parts/partImages/YAM/2/MCY/1975/TX500_TX500A_XS500B/IMAGES/STARTING_MOTOR_UNIT.Gif)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/29 - IT"S ALIVE!!
Post by: SrgtBear on Aug 29, 2010, 20:43:38
Got a new starter rotor with weights in the mail.  Start problem fixed.  Prepare to fire. 3-2-1.  Engine Launch.
http://www.youtube.com/watch?v=U9KU6nX-PVE
This is the first time I ever started it!  Well actually had it running 30 second before I pulled out the camera.  Timing is off but sounds pretty good.  It paid to spend the time adjusting the tappets clearances and points gaps.  Checked compression and all looks goodddd. 
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/29 - IT"S ALIVE!!
Post by: valvesprung on Aug 29, 2010, 23:04:23
Sounds awesome!!! And damn that engine is purty...
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/29 - IT"S ALIVE!!
Post by: JRK5892 on Aug 30, 2010, 12:23:01
ha hahaha that is awesome! sounds just like mine does! tell me that is not a mean sound for a twin! i love it... now the tuning comes in man, i said FK it and ordered some VM30 carbs last week,  done dealing with the ones it has.  let me know if i can help in any way!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/29 - IT"S ALIVE!!
Post by: SrgtBear on Aug 30, 2010, 12:35:22
ha hahaha that is awesome! sounds just like mine does! tell me that is not a mean sound for a twin! i love it... now the tuning comes in man, i said FK it and ordered some VM30 carbs last week,  done dealing with the ones it has.  let me know if i can help in any way!

Thanks.  Yeah definitely sounds means.  quite amazing for such a compact engine.  I only had an minute of fun with the carbs but they didn't seem too bad.  Carbs were super clean from the last guy I bought the bike from.  Didn't have to adjust float bowls or anything.  The only thing I did to them was new o-rings all around and bigger jet.  #135.  There was a little gas drip from the seal of the left pod filter but i think it was from my fuel line clamp not being too tight.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 8/29 - IT"S ALIVE!!
Post by: JRK5892 on Aug 30, 2010, 12:37:06
mine too... spotless actually, i have tried the 135's they did not cut it, actually i have tried 3 up and 3 down from stock, and nothing, floats are perfect, air screw is set, nothing though, i truely hope you have better luck than i did, i think the trick is to run a longer pipe on them, my short shots are just too short
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: SrgtBear on Sep 12, 2010, 22:58:45
Okay first off, forgive me for building this bike backwards.  Now the fun stuff,  hacked up the original seat pan and kept test fitting the fiberglass seat until it sat flat.  Tried to center it as best as possible by drilling a hole in the middle first so i could have a pivot point if i needed to straiten it.  Found some screws, washers, lock washer and a nut.  Cut the bolt to size then use a tap and die set to get the threads back.

Seat works perfectly with hinges.  Now I just gotta give the pan a thorough blasting and epoxy coat.

(http://lh4.ggpht.com/_9MkPMWmQs4I/TI2CSwrfg-I/AAAAAAAAEXk/-B8lW8TVYcU/s640/IMG_1854.JPG)
(http://lh6.ggpht.com/_9MkPMWmQs4I/TI2CWZrbgAI/AAAAAAAAEXs/OkX13srOrHw/s640/IMG_1846.JPG)
(http://lh5.ggpht.com/_9MkPMWmQs4I/TI2CZSnmbHI/AAAAAAAAEXw/WY4X1yBKBEg/s640/IMG_1849.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TI2Cc-G6WWI/AAAAAAAAEX4/ECkpvawfonQ/s640/IMG_1852.JPG)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TI2GaKtZN3I/AAAAAAAAEYI/cA8HrMRF4FY/s512/IMG_1861.JPG)

Just some new decal I photoshop'd up.  Thinking of laying it down on the side of the seat tail.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TI2CeGqwP8I/AAAAAAAAEX8/DHpc7f-dZCI/s912/vinyl.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: teazer on Sep 12, 2010, 23:51:58
I would never have thought of mounting the seat that way, but it looks just right.  Good one.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: JRK5892 on Sep 13, 2010, 12:12:03
that is a great idea fo the seat man!!! just great! to me that seat is a bit long for the bike but the mount set up is def something i will be copy'n in the future!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: SrgtBear on Sep 13, 2010, 12:33:47
that is a great idea fo the seat man!!! just great! to me that seat is a bit long for the bike but the mount set up is def something i will be copy'n in the future!

Thanks.  Yeah I do have to agree the seat is slightly unproportioned compared to the tank and frame.  I measured before hand but I guess you never know how these things are going to fit until you get it in front of you.  Oh well..

I figure it's something you won't even notice once I get it painted.  It just sticks out for now.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: JRK5892 on Sep 13, 2010, 12:36:31
this my friend is true!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: valvesprung on Sep 13, 2010, 12:40:42
I think having the upholstrey wrap 1-2" over the front of the seat hump will help reduce it's visual size a bit., should look tasty.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: SrgtBear on Sep 13, 2010, 12:44:15
I think having the upholstrey wrap 1-2" over the front of the seat hump will help reduce it's visual size a bit., should look tasty.

That's a real good idea!  Thx.  I'll test it out with some photoshop mach ups.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: Swagger on Sep 13, 2010, 14:24:49
Great job mounting the seat...what a good ides. I'm sure it's been done like that but it's the first one I can remember being so cleanly done! Personally I think the seat is 99% there, once upholstery is added (though maybe an inch wrap?) you'll be much closer. The only other thing I would consider is trimming the bottom of the seat hump front the leading edge of the hump up to the top of the flat at the back in a nice gentle arc. That'll shave a ton of 'visual weight; off the ass end in general but specifically it'll tie the seat in better with the tank. If you're still lamenting at that point you could always swap to an XS750 standard tank or a GS450. Both have a great shape for this kind of thing....

Regardless though....great job on the seat mounting!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: SrgtBear on Sep 13, 2010, 14:30:33
Great job mounting the seat...what a good ides. I'm sure it's been done like that but it's the first one I can remember being so cleanly done! Personally I think the seat is 99% there, once upholstery is added (though maybe an inch wrap?) you'll be much closer. The only other thing I would consider is trimming the bottom of the seat hump front the leading edge of the hump up to the top of the flat at the back in a nice gentle arc. That'll shave a ton of 'visual weight; off the ass end in general but specifically it'll tie the seat in better with the tank. If you're still lamenting at that point you could always swap to an XS750 standard tank or a GS450. Both have a great shape for this kind of thing....

Regardless though....great job on the seat mounting!

I think I get what your saying.  Like follow the seat line and trim off the excess that's pops down at the strut bolt area?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/12 - Carpy Seat Mounted
Post by: Swagger on Sep 13, 2010, 15:04:10
standby and I'll show you what I'm talking about......
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: SrgtBear on Sep 20, 2010, 16:40:43
Nothing too exciting here.

Got my Reverse Cone Muffler.  Found the pair on ebay for $100 made by Emgo.  Fitting them was another story.  Had to cut 1.5 to 2 inches off the header ends so I could get the angle right.  Measure twice, cut once.  Universal mounting bracket on the exhaust had nothing to latch on too so I used a electrical pipe clamp with a rubber shim and was able to attach it to part of the frame.

Also fabricated some new side covers.  I just couldn't stand the awful stock ones.  No pics yet but new side covers and going to be an inverted triangle to match the lines of the frame.  30 degrees bent in towards the front with drilled out holes running down it.  Going to put yamaha logo and racing number on it.

(http://lh3.ggpht.com/_9MkPMWmQs4I/TJe1De1KkgI/AAAAAAAAEaM/kjFawClYQPc/s720/IMG_1865.jpg)
(http://lh3.ggpht.com/_9MkPMWmQs4I/TJe1E1-Uu0I/AAAAAAAAEaU/DKyuebHANmg/s576/IMG_1869.jpg)

Next took the rear fender and trimmed the sides so they would be tucked away under the frame.  Then trimmed the tail to fit under the seat.  Now I am water and dirt protected.  Fender is primed in picture.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TJe1FguwQWI/AAAAAAAAEaY/NoavIMAcTu4/s720/IMG_1872.jpg)

Next purchase for tail light.  Drilled Billet Tail light
(http://www.dimecitycycles.com/media/catalog/product/cache/1//5e06319eda06f020e43594a9c230972d/5/3/5349-vintage-cafe-racer-caferacer-bobber-brat-chopper-streetfighter-motorcycle-parts-classic-retro-drilled-taillight-5_2.jpg)
(http://www.dimecitycycles.com/media/catalog/product/cache/1//5e06319eda06f020e43594a9c230972d/5/3/5349-vintage-cafe-racer-caferacer-bobber-brat-chopper-streetfighter-motorcycle-parts-classic-retro-drilled-taillight-6_2.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: JRK5892 on Sep 20, 2010, 16:43:51
you will have no problem tuning that bike with those pipes! not at all man, that is what i should have gone wiht from the jump... but now i am too deep!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: JRK5892 on Sep 20, 2010, 16:45:11
it is looking great so far man! did you see how i did my side covers, that would be a good way to run with them but do much more of the screen work
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: SrgtBear on Sep 20, 2010, 17:07:42
it is looking great so far man! did you see how i did my side covers, that would be a good way to run with them but do much more of the screen work

I liked your side covers alot.  I think if I kept mine I would do the same.  The problem is that I hate how they overlap the edge of the frame and hide the pod filters.  So the other day I cut out two steel pieces in the shape of the image below.  Bent in the seam to follow the frame and drill holes with a mesh back.  Racing number or logo on the side.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TJe99zyPugI/AAAAAAAAEak/PvgG-XDZtUk/5.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: Royal on Sep 20, 2010, 21:39:28
I like the side cover idea, should look cool.

I noticed you decided to keep the passenger foot peg mount loops on the frame.  I'm planning to cut mine off.  Any thoughts on that?

BTW the bike is looking great.  Have you decided on the paint yet?

I am planning to go with something a little crazy:

(http://lh6.ggpht.com/_KCUetzKkzgQ/TJf-B4NH2aI/AAAAAAAABNk/rpZYfOejEyw/s640/IMG00042-20100815-1507.jpg)

Or something conservative like Audi Nimbus Grey:

(http://ll.speedhunters.com/u/f/eagames/NFS/speedhunters.com/Images/Jacco%20Willemsen/Events/Bilsport%2009/28448.jpg)

LOL, I can't decide.

Anyway, what did you do about your electrical?  I wan't to redo mine completely and eliminate my starter.

Cheers,

R.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: SrgtBear on Sep 20, 2010, 22:02:07
Rearsets have been on my list but there are a couple things that complicate the idea.  First is that there is really not much room with the exhaust muffler in the way.  If you look at Joe's TX500 he was able to pull it off because he has strait pipes.  My other concern is that the angle of linkage would rub against the case.  Thus I would have to reverse the shifting.  1-UP 2,3,4,5 down.

I am going to ride with the stock setup first and see how it rides then decide what i want to do.  I kept the start and everything.  Just easier to start up.  Joe fabricated a start switch on the side of his TX500.  Really slick looking.

I've recently decide to go with a candy apple red paint with black racing strips.  I was going to do candy and silver but the black will flow better with my black spokes.

Here is mach up I did awhile ago.  Side covers are out now.  New ones will be black. with white racing number or something.
(http://lh6.ggpht.com/_9MkPMWmQs4I/TET5hYyg9UI/AAAAAAAAEMc/E7IHtes3GQI/s640/MACK-UP-BLACK.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: JRK5892 on Sep 21, 2010, 11:12:56
i like the colors!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: Big Rich on Sep 21, 2010, 11:42:10
Just saw this - that reverse shifting (normally called GP shifting) can actually be comfortable once you get used to it. Problem is, it can also be habit forming..... Especially if you ride more than 1 bike.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 9/20
Post by: JRK5892 on Sep 21, 2010, 11:45:21
i have rode GP shifting and personally hate it, exp in traffic! but then again i have been riding standard shift for years, it also makes selling the bike hard!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Sooo Close - 10/17
Post by: SrgtBear on Oct 17, 2010, 19:33:02
It's been awhile since I made any updates.  I took a few weekends off and took a trip down to Austin, TX to visit a friend then a trip to DC the weekend after for a party.

Anyways, the bike is so close to being done I can taste it.  Not much left.  Mounted rear tail light which looks bitchen and finally got the hardware for the center stand.  The center stand is a bitch to put down but it looks cooler and sits safer.....thats if you don't drop your bike trying to put it down.  If someone has a better technique let me know.  Right now it involved standing on the center stand and pulling the rear up by the frame.  I only weight 150lb. Pics below.

To do list:
Rebuild Petcocks
Rear Turn Signals
Front Fender
Upholster Seat
Bondo Tank to clean up knee inserts
Prep & Paint

(http://lh3.ggpht.com/_9MkPMWmQs4I/TLt1mZT6mYI/AAAAAAAAEc0/jpWSpi8TTek/s640/IMG_1905.JPG)(http://lh4.ggpht.com/_9MkPMWmQs4I/TLt1otb23qI/AAAAAAAAEc4/XzCiodKQVwQ/s512/IMG_1909.JPG)(http://lh5.ggpht.com/_9MkPMWmQs4I/TLt1rPkdIVI/AAAAAAAAEdA/zbnkP49spSg/s640/IMG_1912.JPG)(http://lh6.ggpht.com/_9MkPMWmQs4I/TLt1tTxtZII/AAAAAAAAEdE/H0WO56JSBOE/s640/IMG_1913.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: SrgtBear on Apr 03, 2011, 11:52:19
Current status.  It's been test driven.  It sounds mean.  It feels mean.  It just needs a seat cushion, paint, and carb sync.  All done very soon. :) :) :)
Things you may notice include bondo tank work.  Formed knee inserts after I hammer them in a little.  New taillight.  Turn signal below the seat.  All blinking correctly after I added some resistors.  Also cut front fender.  My only regret is that I didn't take video of the test drives.  Other than that timing has been adjusted and just needs a carb sync.
(https://lh6.googleusercontent.com/_9MkPMWmQs4I/TZiGGSLEnfI/AAAAAAAAEvA/Et4-Hn6k5ds/s800/0327111018.jpg)
Before Bondo Work, rear turn signals and front fender:

(https://lh6.googleusercontent.com/_9MkPMWmQs4I/TZiIbkyvkKI/AAAAAAAAEvI/7hDrHnNbCzM/s800/1016101625.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: saywhat on Apr 03, 2011, 12:38:13
Glad to see you back in action!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: two-smoker on Apr 03, 2011, 13:28:05
Looking good!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: Swagger on Apr 04, 2011, 16:14:39
That's coming together really nicely, one of my favorite 'unsung' motors too!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: JRK5892 on Apr 04, 2011, 16:15:43
the motor looks awesome! what jets you runing on those carbs with pods?
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: SrgtBear on Apr 04, 2011, 16:23:51
the motor looks awesome! what jets you runing on those carbs with pods?

#135

It fires up and runs with no problem.  However I just noticed I am having low idle problems.  Firing of 1 and 1/2 a cylinder. (Right Cylinder weak at idle and slow turns.)  I know it's timed correctly because mid and top end runs at tip top shape.  Gotta go back and check the float bowl height and sync carbs.

As far as the jet, I haven't been able to tell if it's running to rich, but I am having great mid-range and top-range.  No smoke.  I'll check the plugs later.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: JRK5892 on Apr 04, 2011, 16:28:12
same thing i was running into... problem is onece the carbs where synced the motor would race at idol after i came off the throttle while riding. so i would lwoer the idol then it would die... i got sick and tired of fussing with it... hope you have better luck. I changed carbs. keep me updated bud bike looks great!
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: saywhat on Apr 04, 2011, 16:50:41
I hope you guys figure out the carb issues before I get mine up and running, I'm not looking forward to the impossible tuning with pods and open exhaust :(
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: SrgtBear on Apr 04, 2011, 16:58:11
I hope you guys figure out the carb issues before I get mine up and running, I'm not looking forward to the impossible tuning with pods and open exhaust :(

I am going to be honest.  I don't think the open exhaust setup works on this bike.  I think back pressure is the key to this bike.  I read alot of stuff on the internet and kept hearing the same things.  I don't have quite the same symptoms as Joe.  My idle doesn't shift up and down.  My one cylinder is just weak or not firing at idle and low rpms.  According to the service manual the float bowl may not be sitting right. (which makes perfect sense for my problem.)  Still I would try to figure something out for an exhaust.

These reverse cones on mine are super nice. They still sound real great and loud with the baffle.  They will come with couplers to get them to fit right.  I had to cut about 1 inch and 1/2 off the end of the headers to get them to go strait.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: JRK5892 on Apr 04, 2011, 17:10:53
i ahve full baffles in my pipes as well i could not even come close to get the bike run with open pipes, plus it sounded like crap
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: Swagger on Apr 04, 2011, 17:21:09
SrgtBear has hit it on the head.
Lots of guys will swear up and down that you can run CV carbs open, with Velocity stacks or pods. While it *can* be done, the simple fact is it takes a LOT of tuning and several key mods. You can drill out the transfer port(s) in the slide and take care of some of it but not all. I saw a bike with an external vacuum reference added to each carb but talk about beating a dead horse! You could make chambers that slip onto the mouths of the carbs from ABS plumbing pipe, say...8" long with a partially blocked opening and slip long foam filters over the whole length to hide the tube. That might help but again.....pounding away at the deceased equine.

The problem is that without the OE back-pressure at the mouth of the carb that is given by the stock airbox, and some additional back pressure from the exhaust....the slides in those CV carbs simply won't meter the fuel correctly. The results are often boggy throttle response (already one problem with CVs), hanging idle, erratic idle, burned pistons, stinky feet and bad breath.

The simplest plan to get this running smoothly would be to sling the stock airbox back on and re-jet to suit your more open pipes. That would certainly be adequate if not entirely bitchin.

Or......
go to your parts retailer of choice and pick up a pair of VM30's and jet them as needed to run your pipes and open element intake. Not only will you have manual control of the metering via the throttle cable itself but you will have a far broader range of tuning.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: two-smoker on Apr 04, 2011, 19:47:59
I never even tried to run stock carbs on mine... The mikunis showed up last Thursday, along with my new tank off a 78. So that's what I'm running. I've heard bad things from too many people. What gets me is, I had no trouble running keihin cv's with pods and an open exhaust on my cb450....
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: Big Rich on Apr 04, 2011, 22:20:29
Looks great Srg- I still love that chrome on the motor.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: saywhat on Apr 05, 2011, 13:44:32
Do you guys have the BS38 Mikunis, or the earlier Keilins (sp?), I guess they changed to Mikunis in '76 and they are supposed to be a little more tune/bolt-on friendly.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: Rossicle on Apr 07, 2011, 04:12:03
I'm blown away by that engine! It's beautiful! Can't wait to see the rest of the bike finished.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Long Awaited Update - 4/3
Post by: two-smoker on Apr 07, 2011, 17:34:53
Do you guys have the BS38 Mikunis, or the earlier Keilins (sp?), I guess they changed to Mikunis in '76 and they are supposed to be a little more tune/bolt-on friendly.

I had the earlier Keihins. Now I have Mikunis. (sorry to thread jack)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Baby's got some fine lines 4/17
Post by: SrgtBear on Apr 17, 2011, 23:39:36
Got some new pics.  Trying to stay more active on here as much as I can.  Also trying to keep busy on my bike with the peak of the summer right around the corner.  My upholstery guy was away this weekend so I'll have to wait till next weekend to drop off the seat.  The good news is that I was able to work on a couple odds and ends.

Below you'll see the front fender and side covers.  I scuffed up the front fender real good and put a layer of bondo on it so I could paint on it later.  It's a little short so at this point it's mostly about looks.

I kept cutting the side covers down until I got the lines I wanted.  I'll fill in the dents and stuff before I paint.

Finally, a complete picture with fender and side cover.  I got the admit that the bike has some great lines.  Came together real nice.

P.S.  I am missing a rubber grommet for the upper right corner of my left side cover.  If anyone has an extra one I could definitely use it.
(https://lh3.googleusercontent.com/_9MkPMWmQs4I/TaufvHejl-I/AAAAAAAAEzU/TKpJAmJVFCI/s640/IMG_2280.JPG)
(https://lh4.googleusercontent.com/_9MkPMWmQs4I/Tauf2-zhwkI/AAAAAAAAEzg/RPLiwMYB4CQ/s640/IMG_2279.JPG)
(https://lh5.googleusercontent.com/_9MkPMWmQs4I/TaufqGup36I/AAAAAAAAEzI/b-PMjNtUWLI/s512/IMG_2282.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Paint: Your Vote is Needed. 5/1
Post by: SrgtBear on May 01, 2011, 11:03:44
I've been throwing around paint schemes for the last year and now I finally ready to lay it down.  I think at this point I could use some peoples opinions on which way I should go.  REDnBlack or BlacknRed?  Personally I love them both.  Below are the samples I'll be working with, followed by my poopy photoshop mach-ups.  Let me know what you think.
(http://www.tcpglobal.com/images/rsp1901.jpg)(http://www.tcpglobal.com/images/rsp2701.jpg)

REDnBLACK:
(https://lh6.googleusercontent.com/_9MkPMWmQs4I/Tb1mozVRwRI/AAAAAAAAE2c/6DovhGzlDd4/s800/MACK-UP-REDnBLACK1.jpg)

BLACKnRED:
(https://lh6.googleusercontent.com/_9MkPMWmQs4I/Tb1movzqRBI/AAAAAAAAE2Y/QsXd34GLwSg/s800/MACK-UP-BLACK-nRED.jpg)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Paint: Your Vote is Needed. 5/1
Post by: valvesprung on May 01, 2011, 12:59:26
Red usually isn't my thing, but I say REDnBLACK all the way man. Looks crazy classy...
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - Paint: Your Vote is Needed. 5/1
Post by: SrgtBear on May 02, 2011, 13:58:56
Timing and Carbs Synced this weekend thanks to this bad boy.  A little jump and hesitation when down shifting and slowly rolling on the throttle.  The culprit is probably the the pod filters on the CV carbs.  Very minor though to the way she rides and feels now. All smiles.  :D

Best $100 dollar investment that paid for itself.  Plans to give it many more uses. http://www.thealphamoto.com/servlet/the-246/Carburetor-Synchronizer-carb-sync/Detail (http://www.thealphamoto.com/servlet/the-246/Carburetor-Synchronizer-carb-sync/Detail)
(http://www.thealphamoto.com/media/01/a20791a12cb76c484b4074_m.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 5/2
Post by: Rossicle on May 03, 2011, 06:32:12
I could really use a set of those! So handy.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 5/2
Post by: SrgtBear on May 03, 2011, 08:36:15
I could really use a set of those! So handy.

yeah, they even have built in dampers so you can level out the needle bounce.  solid investment with a protective hardcase.
Title: Re: 1975 Yamaha XS500B Cafe Project (TX500) - 5/2
Post by: Rossicle on May 04, 2011, 02:09:25
I might just have to look into that this summer when I get the cash!
Title: Re: 1975 Yamaha XS500B Cafe Project - 5/15 - Preview: Paint Test Spray
Post by: SrgtBear on May 15, 2011, 23:18:25
Called my upholster on the seat situation.  Another week!  That's 4 weeks total.  :'(   In the meantime, I did a little of work on the side covers and went thru some test sprays.

So with out delay here is a little preview of things to come in the next few weeks!
(https://lh6.googleusercontent.com/_9MkPMWmQs4I/TdCEwsvXppI/AAAAAAAAE4k/1wlqQJgKyxk/s512/IMG_2350.JPG)(https://lh3.googleusercontent.com/_9MkPMWmQs4I/TdCEq66PLOI/AAAAAAAAE4g/b1g1yxtN308/s512/IMG_2347.JPG)(https://lh6.googleusercontent.com/_9MkPMWmQs4I/TdCEli7LJGI/AAAAAAAAE4Y/JjVWVVdXGpE/s640/IMG_2378.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project - 5/22 - Final Stage...almost
Post by: SrgtBear on May 22, 2011, 15:18:03
Upholster finally finished up.  Now I got a seat.  Now the only thing remaining is bodywork and paint.  Next time I post this nearly 2 year project will finally be done!
(https://lh5.googleusercontent.com/_9MkPMWmQs4I/TdlRluLhBRI/AAAAAAAAE7U/vBRo4lK8Iq8/s640/IMG_2382.JPG)
(https://lh4.googleusercontent.com/_9MkPMWmQs4I/TdlRnsPYSDI/AAAAAAAAE7Y/PznOw-LWFo4/s640/IMG_2383.JPG)(https://lh6.googleusercontent.com/_9MkPMWmQs4I/TdlRjmt-CRI/AAAAAAAAE7M/WEeEyKprBmc/s640/IMG_2381.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project - 6/9 - Final Stage...Preview
Post by: SrgtBear on Jun 09, 2011, 10:38:11
I was hoping to post final pictures but unforuntely I've had some delays with having to work and a weekend weather forcast with 87% humidity.  So for now the bike is on hold until a have a nice humidity free weekend.

I decided to go with Duplicolor PaintShop system.  However after some test sprays I have noticed the candy was too thick.  I sprayed a gold base and a silver base.  After I sprayed the candy I couldn't tell the difference due to the thickness.  Since then I have bought some Laquer Thinner and will play around with some test spray.  In addition, after reading much about the cons of laquer I have decided to purchase a ppg polyurethane clear that will hopefully protect it a little bit longer when it comes to the durability and chemical resistance.

Here is a little preview for now and my latest purchase:
(https://lh6.googleusercontent.com/-XQDsBofjS9E/TeW0lQofQtI/AAAAAAAAFAw/4sBI_1ocDLs/s640/IMG_2450.JPG)
(https://lh5.googleusercontent.com/-m13wOrHuc7Y/TfDIjOgUETI/AAAAAAAAFBw/93lX2ApgatI/s640/IMG_2458.JPG)
Title: Re: 1975 Yamaha XS500B Cafe Project - 6/9 - Final Stage...Preview
Post by: JRK5892 on Jun 09, 2011, 11:17:35
Solid man!!! please keep us updated... i was planning on shooting the gloss black and clear on my fairing and saddle bags this weekend for my harley... would love some feedback... what tip are you using?
Title: Re: 1975 Yamaha XS500B Cafe Project - 6/9 - Final Stage...Preview
Post by: SrgtBear on Jun 09, 2011, 12:02:42
Solid man!!! please keep us updated... i was planning on shooting the gloss black and clear on my fairing and saddle bags this weekend for my harley... would love some feedback... what tip are you using?

standard 1.5mm tip.  My girlfriend's brother is a painter in an autobody shop.  He gave me some pointers for adjusting the gun.  This video also helped alot.  I will definitely keep you posted on the results.
Auto Spray Paint Gun Adjustments and Tips - How To Adjust A Paint Gun (http://www.youtube.com/watch?v=U-acl0BNGWk#ws)
Title: Re: 1975 Yamaha XS500B Cafe Project - 6/9 - Final Stage...Preview
Post by: cloudhopper on Jun 11, 2011, 04:39:10
hello,


i believe i missed the post, but what tank are you running on your 500?



Title: Re: 1975 Yamaha XS500B Cafe Project - 6/9 - Final Stage...Preview
Post by: SrgtBear on Jun 11, 2011, 07:42:07
hello,

i believe i missed the post, but what tank are you running on your 500?

stock tank.  used a plastic ball end mallet and hammer the sides in then spent days of shaping with bondo. 
Title: Re: 1975 Yamaha XS500 Cafe Project - 6/12 - Steering Damper Equiped
Post by: SrgtBear on Jun 12, 2011, 18:59:09
Last minute addition.  Motivated by Joe's Flat Out Steering Damper.  Installed this NHK 7-way steering damper and 34mm fork bracket from MikesXS.net.   A little annoyed that neither part came with any bolts except for clamping portion of the fork bracket.

Anyways the damper installation took about a day and half.  Fabricated 1 bracket but it was too weak.  Then finally figured out a way to fabricate a stronger bracket to mount right inside the tank area.  Don't ask me how I did it because it was too painful mentally and physically to explain and create.  The bracket itself is pretty sturdy but it does show a little weakness on the dampers max stiffness.  It's pretty close to the durability and strength I was looking for.  It will have to do for now.
(https://lh5.googleusercontent.com/-uvSktp5ZOyU/TfU0JuzZxJI/AAAAAAAAFDE/RblYxuMWje0/s640/IMG_2461.JPG)
(https://lh3.googleusercontent.com/-BOMbEeE8sQ8/TfU0SR8QCxI/AAAAAAAAFDU/G8xI-Q3ximA/s640/IMG_2463.JPG)
Title: Re: 1975 Yamaha XS500 Cafe Project - 6/12 - Steering Damper Equiped
Post by: JRK5892 on Jun 13, 2011, 12:13:56
very nice! i run the same spot on damper on the brat wing! your gonna love it
Title: Re: '75 Yamaha XS500 Cafe Project - 6/20 - White Base for Strips & Frog Tape
Post by: SrgtBear on Jun 20, 2011, 10:38:46
Laid down White Base for Stripes & Frog Taped the racing strips.  I'm only going to give you a preview of the tank and front fender for now.  You'll get the see the rest when it's done.  :P
(https://lh5.googleusercontent.com/-HcRjOIxkS0Q/Tf9KtR3MifI/AAAAAAAAFEo/GXbdvPHPTAo/photo2.JPG)
Title: Re: '75 Yamaha XS500 Cafe Project - 6/20 - White Base for Strips & Frog Tape
Post by: Iamme9878 on Jun 20, 2011, 10:42:52
Looks nice, Im Cafing My 1980 Yamaha XS850LG Midnight Special

Title: Re: '75 Yamaha XS500 Cafe Project - 6/20 - White Base for Strips & Frog Tape
Post by: valvesprung on Jun 20, 2011, 12:21:50
EXCITED...
Title: Re: '75 Yamaha XS500 Cafe Project - 6/20 - White Base for Strips & Frog Tape
Post by: Swagger on Jun 20, 2011, 13:22:22
Dunno man, I'm kinda digging the white and green!
Title: Re: '75 Yamaha XS500 Cafe Project - 6/20 - White Base for Strips & Frog Tape
Post by: SrgtBear on Jun 20, 2011, 14:26:23
Dunno man, I'm kinda digging the white and green!

ha that's what all my friends are saying.  I already bought my supplies soo I'll save the white and lime green or black and lime green for the next build.  ::)
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Jul 05, 2011, 09:46:05
Well, here it is.  Everything is here minus the kick starter.  Have to pop off the clutch cover at some point to fix the spring.  I was hoping to get a professional photographer but here are some pics in the meantime.
(https://lh5.googleusercontent.com/-1-Zd4iCoqe8/ThMFvQysJCI/AAAAAAAAFXI/fa6vW7V8evg/s800/photo3.JPG)(https://lh6.googleusercontent.com/-gk1cs-X6kwY/ThMFsv-U2HI/AAAAAAAAFW0/LysrvOQpt7g/s640/Neko%252520015.jpg)(https://lh4.googleusercontent.com/-GLjk4tQgLjQ/ThMFteojyAI/AAAAAAAAFW4/IvkVwdbM8os/s800/Neko%252520021.jpg)(https://lh5.googleusercontent.com/-DJNiz9zLDqA/ThMFuPCJaYI/AAAAAAAAFW8/1zp3GernFDU/s800/Neko%252520022.jpg)(https://lh5.googleusercontent.com/-PxFASV1y4NQ/ThMFt2yWICI/AAAAAAAAFXg/17XuCpYUCBk/s800/Neko%252520012.jpg)(https://lh4.googleusercontent.com/-VDFzDwWjDCw/ThMFvoCiP3I/AAAAAAAAFXQ/qsMSO1cfcyc/s640/photo4.JPG)

And finally, me with my baby
(https://lh3.googleusercontent.com/-yV8rwy0k0rg/ThMFuScOawI/AAAAAAAAFXE/Yw6uhGzyQjo/s800/photo1.JPG)
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Jul 05, 2011, 09:48:24
More pics and video to come soon...
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: CrescentSon on Jul 05, 2011, 10:12:19
She turned out stunning Sarge. Damn nice work.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: JustinLonghorn on Jul 05, 2011, 10:16:22
Yes sir,
 
I can dig it.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Jul 05, 2011, 10:18:27
She turned out stunning Sarge. Damn nice work.
Yes sir,
 
I can dig it.

Thanks,  Candy paint really pops in the first picture.  Gotta catch it in that right lighting and angle.  Looks way better in person.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Big Rich on Jul 05, 2011, 10:21:31
Great work Ted! There is a lot of attention to detail on here. Congrats man!
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: milehigh on Jul 05, 2011, 11:22:47
she is one purdy lady. well done sir.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: oohsam on Jul 05, 2011, 11:39:39
That is pure sex.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Kanticoy on Jul 05, 2011, 13:28:53
Very nice bike.

Sent from my ADR6300 using Tapatalk
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: two-smoker on Jul 05, 2011, 15:49:41
The candy red is really nice.... of course, I WAS planning on painting my bike the same color! Guess I'll stock with my earlier plan....
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: JRK5892 on Jul 05, 2011, 15:54:03
how did you like the shop line paint? that is a bit different then they sell at the store (autozone) bike looks great!!!!
waht jetting did you end up going with? glad those carbs worked!!!

man she looks great! let me knwo on that paint!
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Jul 05, 2011, 15:54:40
The candy red is really nice.... of course, I WAS planning on painting my bike the same color! Guess I'll stock with my earlier plan....

lol.  sorry man.  You can always go with the white and lime green paint scheme.  Others seemed to enjoy some of my earlier pics with the white base and lime green frog tape.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Jul 05, 2011, 16:06:28
how did you like the shop line paint? that is a bit different then they sell at the store (autozone) bike looks great!!!!
waht jetting did you end up going with? glad those carbs worked!!!

man she looks great! let me knwo on that paint!

PPG Shop-Line clearcoat was pimp.  I used to Duplicolor Paintshop arylic laquer setup for my base.  The key to getting the candy to pop is to wet sand it down so the metallic underneath just starts to show.  Then the PPG Shopline clearcoat turned out spectacular.  comes out glassly after 8 hours with medium hardner.  Nice a durable.  Pepboy's still sells the candy paints.  My only suggestion is that you take off any tape after a few hours when it's still a little tacky.  When it hardens tape will be hard to get off. 
Also it likes to drip so watch the heavy coats. 

The carbs are working great except I am having overheating issues at long idles.  I re-synched the carbs but I need to check my plugs, timing, and maybe valves again.  Cylinder head temp got up to 340F the other day then stalled.  I am pretty sure it's jetted rich but I need to double check with the plugs.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: t71ford on Jul 06, 2011, 02:02:25
Hot damn, Sarge!! Looks stunning! I really dig how this thing came together, especially for an XS!
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Ringo on Jul 06, 2011, 02:12:44
Very nice indeed!  Ya know, I'm almost never a fan of chrome, but I really dig it here.  It's actually...different(!) on these old bikes. 

(your covers are chromed, right?  Or am I an idiot?)

Either way, bravo.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: YogiBear on Oct 21, 2011, 03:26:23
Excellent looking bike!  ;)
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Swagger on Oct 21, 2011, 21:03:37
Wow!! That really turned out nice, I official rescind my previous statement....that red is made of win. I don't know if it's been covered (sorry for the skim, I have parts running) but what paint is that exactly?
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: joea on Oct 22, 2011, 02:46:21
nice clean bike...good job.
joe@ vcycle
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: JRK5892 on Oct 24, 2011, 12:40:54
how was the shop line paint bud?
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: cowboysculptor on Mar 31, 2012, 13:48:14
I just read through this build thread, and let me say, GREAT job! I'm in love with the old TX/XS500's.

You mentioned it runs hot. These bikes are notorious for running hot, the heads are known to crack at the exhaust ports, so be careful! I would seriously look into an oil cooler for it. You haven't posted in a while, so I hope you get this.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Apr 04, 2012, 12:56:49
I just read through this build thread, and let me say, GREAT job! I'm in love with the old TX/XS500's.

You mentioned it runs hot. These bikes are notorious for running hot, the heads are known to crack at the exhaust ports, so be careful! I would seriously look into an oil cooler for it. You haven't posted in a while, so I hope you get this.

Thanks man.  Yeah, it only runs hot in the dead heat of the summer.  Otherwise this kind of weather the bike is in heaven.  No problems yet...  Oil cooler idea crossed my mine but the adaption is not easy.  Joe, another DTT member had done it but it required grinding away have of the side cover so the aftermarket fitting could fit.  Mine are chromed so that def won't be happening, lol
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: two-smoker on Apr 05, 2012, 03:43:07
If you're looking, for an easy way to fit an oil cooler, why not use the oil feed on the back of the cylinders as a start? It secures just like a banjo bolt on either end. It wouldn't be hard to actually use banjo bolts with barbed fittings,  and oil cooler hose. Then you're feeding cool oil directly where it needs to go.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Apr 05, 2012, 09:08:40
If you're looking, for an easy way to fit an oil cooler, why not use the oil feed on the back of the cylinders as a start? It secures just like a banjo bolt on either end. It wouldn't be hard to actually use banjo bolts with barbed fittings,  and oil cooler hose. Then you're feeding cool oil directly where it needs to go.

That's actually not a bad idea.  The question is will it keep the right amount of oil pressure to keep the valve and cam's nice a lubricated.

Ted
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: two-smoker on Apr 05, 2012, 10:30:37
Well, I look at it like this; as long as there's no air in the lines, the volume of oil being pumped isn't going to change. Plus, any pressure lost through the larger ID of a rubber line will just step back up when it goes through the banjo at the other end. And fluid doesn't compress. I may be wrong, but it's not going to stop me from trying it myself.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Apr 05, 2012, 11:06:48
Research how the pro fitted oil coolers to these things.Oil in coolers can often cool to the point where it slows the flow to vital parts.Just run good synthetic MC oil in it and it should be fine.

Been using Rotella and so far so good.  Gotta love nice and strong diesel engine oil.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: JRK5892 on Apr 05, 2012, 11:07:19
DO NOT RUN A SYNTHETIC IN THIS BIKE! the clutch plates will slip.. the friction modiers in synthetic will cause sub clutch plates to slip... seen it over and over... rotella in any bike 95 and below
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Swagger on Apr 05, 2012, 22:42:39
And the right choice is the proper oil for the job. If you're clutch is oil bath....and it is in this bike, DO NOT run synthetic or semi-synth. Your clutch will fail. And running synthetic to address a known heat issue is patently silly. You gain nothing and cause all manner of trouble with clutches and seals that aren't designed for it.

Give sound advice not anecdotal or give it a rest.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Swagger on Apr 05, 2012, 23:55:29
Again, purely anecdotal.

Yes, synthetic oil is far superior to dinosaur juice but..........only in a system that's designed for it. This engine was not and your original "advice" is still stupid. Synthetic oil is not a good or even slightly useful (or even slightly effective) way to drop engine temps which is what leads the early XS500 heads to crack. Seriously, if you can't give good advice just give it a break.

to the OP: Ask a trained tech what he says and do that, not what some guy(myself or anyone else) on the internet says. Bet I know what that trained tech is gonna tell you though.
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: JRK5892 on Apr 06, 2012, 10:46:51
Swivel, i am glad to hear you have had goodl luck with synthetic on submerse clutch bikes... i have built around 15 or so now and any time i run synthic in one or semi (cause i have the oil laying around the shop) i get clutch slip... bad... i have had prob 50 customers bikes come though the shop (we are one of the only shop in the area that will touch 70's and 80's bikes... come in for "new clutch" i swap the oil in them... let them sit with a zip tie around the clutch lever to open up the plates for a night in rotella, and boom... issue goes away! I am glad you have had good luck but the friction moddiers that are in syntheic oils create issues with clutches that use engine oil. It is not a opinion or any BS, it is simply a fact... you are able to use a semi some how, that is awesome... however it completely goes against everythign that i have seen come though my shop doors... but then again, there is an exception to every rule... for the record... i only run synthetic in my harleys or V twin customer bikes.. hell i even do a 20oz additive of treatment (lucas) to get rid of valve train noise... works far better than dyno oil...
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: Cloyd on Apr 06, 2012, 12:31:04
I love that tank it looks really good. 
Title: Re: '75 Yamaha XS500 Cafe Project - 7/5 - DONE!!! FINISHED!!! COMPLETE!!!
Post by: SrgtBear on Apr 09, 2012, 14:26:12
I love that tank it looks really good.

Thanks.  I am proud to say I took her for a really long spin this weekend and she reached a milestone of 70 mph and kept pulling hard.  Got smoother the faster I went. 

The best part about it is that the engine cylinder temp maintained around 250F.  Perfect!

Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: SrgtBear on Aug 05, 2012, 11:53:37
Here are some long overdue riding videos.  The bike was finished last summer.
http://www.youtube.com/watch?v=gnSJUq2hDQk
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: Architecterre on Aug 05, 2012, 18:49:34
Couldn't tell if that was a video of your bike or a subliminal advertisement for Honda Accord ;)
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: rundown on Nov 08, 2012, 13:38:52
SgtBear;
What an excellent thread.  I just bought a similar bike, although I doubt I can build anything nearly as nice as yours.
Thank you for sharing the build with us.
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: SrgtBear on Nov 08, 2012, 14:19:19
SgtBear;
What an excellent thread.  I just bought a similar bike, although I doubt I can build anything nearly as nice as yours.
Thank you for sharing the build with us.

Thanks!  It really wasn't that challanging.  Just time consuming.  If I can do it, you can do it.  Just use your imagination and problem solve.  Where there is a will there is a way!  :)

Ted
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: JRK5892 on Nov 08, 2012, 14:43:57
there is also alot more help out there from when he and i built our Tx's just ask for help when you need it man
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: JRK5892 on Nov 08, 2012, 14:45:55
jesus how did i miss the 2-1 pipe!!! where the hell did you source that! going to have to go back into your posts and do some reading...
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: SrgtBear on Nov 08, 2012, 16:46:46
jesus how did i miss the 2-1 pipe!!! where the hell did you source that! going to have to go back into your posts and do some reading...

Hey Joe,  Believe it or not that 2-1 pipe came with the bike.  I hunted down strait pipe headers and almost sold these before I realized how much the better the bike runs with the 2-1 setup.

Original Pic:
(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/10218_584523478557_2859834_n.jpg)

1-1 Exhaust:
(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/284522_750971749887_596076_n.jpg)

2-1 Exhaust: (LEFT) (RIGHT)
(http://sphotos-b.xx.fbcdn.net/hphotos-ash3/557105_4718270920870_804492140_n.jpg)
(http://sphotos-b.xx.fbcdn.net/hphotos-ash4/382602_811571133237_665254470_n.jpg)
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: Ichiban Moto on Sep 05, 2013, 10:51:54
That's one bad  ass bike ! It really inspires me. 

I just bought a XS500 ... If mine turns out half as good as yours, I will be very happy
Title: Re: '75 Yamaha XS500 Cafe Project - 8/5 - Videos Long Overdue
Post by: SrgtBear on Sep 05, 2013, 11:05:27
That's one bad  ass bike ! It really inspires me. 

I just bought a XS500 ... If mine turns out half as good as yours, I will be very happy

Thanks, if I could make some recommendations I would avoid chroming the engine not only due to cost but also far ventilation.  The chrome plating retains heat.  Also, check your compression per cylinder.  Make sure they are within service manual spec.  If not, do a top end rebuild with new piston rings.  It might seem like alot of work but it will save headaches in the future.  Good luck!

Ted
Title: Re: '75 Yamaha XS500 Cafe Project - 4/10 - Engine Tuned
Post by: SrgtBear on Apr 25, 2014, 12:10:58
I finished this bike a long time ago but have always having a little bit of problems with getting the engine to run just right.  After two years of building my beauty and two years of trying to figure out why it's not running right I think i finally found the answer. It all started when I realized the idle was off from the Aftermarket to OEM tac ratio. Also pulled out the air mixture screws and found gunk behind them. From there this is what I did:

1.) Compression Test L: 140psi, R: 145 psi
2.) Rejet - 50 slow jet, 120 main with pods and 2-1 exhaust
3.) Hook up old tac and set idle at 1200 rpms
4.) Synced carbs to both run at 20cfHg vacuum pressure according to manual spec 15-20 required.
5.) play with air mixture screw until idle sounded at it's best

I took her for a quick spin and the power band was nearly smooth as glass. I realized at some point prior i put shims on the needle so I am going to go back and take those out and hopefully everything should be perfect. I had also let it idle for a long time 20-30 minutes and it was getting a little hot but a 20-30 minute idle probably would never occur while riding. So once I go through the needle i'll take it for a real spin and test drive and post a video!

Heres a video of what I did and how I did it:
https://www.youtube.com/watch?v=Fc30ABUB6Ps
Title: Re: '75 Yamaha XS500 Cafe Project - 4/25 - Engine Tuned
Post by: JRK5892 on Apr 25, 2014, 12:35:17
awesome!!! going to have to copy this move!
Title: Re: '75 Yamaha XS500 Cafe Project - 4/25 - Engine Tuned
Post by: JRK5892 on Apr 25, 2014, 12:41:31
i really should say fuck it and get the same pipe, i lvoe that sucker
Title: Re: '75 Yamaha XS500 Cafe Project - 4/25 - Engine Tuned
Post by: SrgtBear on Apr 25, 2014, 12:46:12
i really should say fuck it and get the same pipe, i lvoe that sucker

it's a nice pipe.  not too loud but still sounds nice.  hope you can find one somewhere.
Title: Re: '75 Yamaha XS500 Cafe Project - 4/25 - Engine Tuned
Post by: SrgtBear on Apr 11, 2016, 18:32:07
Just uploaded a video of me ripping on throttle.  Thought I would share.  Enjoy!
https://www.youtube.com/watch?v=6lnU85l4wTY