collapse

www.dimecitycycles.com

https://www.townmoto.com/collections/vanson-leathers


www.restocycle.com

www.CITYLIMITMOTO.com

www.jadusmotorcycleparts.com

www.bisonmotorsports.com

www.speedmotoco.com

www.lostapostlejewelry.com

www.cognitomoto.com

www.sparckmoto.com

www.pistonsociety.com

www.steeltowngarage.com


Author Topic: 81 Honda XL500 Scrambler  (Read 6356 times)

Offline cascade_crawler

  • Posts: 10
81 Honda XL500 Scrambler
« on: Jun 15, 2016, 18:20:41 »
Been a long time coming, but I finally got around to getting all my pictures together and making a little build thread for this bike. 

I acquired this bike several years ago with plans to build it into a scrambler/street tracker at the very beginning of it being "cool" to do so. Unfortunately I drug my feet and it just got done recently, so much for being a trend setter ;D
I got it off craigslist for cheap and it ran and rode, but had a massive oil leak.  It poured oil straight from the head onto the exhaust and made it appear my bike was on fire.  I later learned this was a common issue with this generation of motor, and it would be a little more work to fix than a simple gasket.   

I liked this bike for 2 main reasons: It had the same tank and dual shock setup of moms old xr200 that I learned how to ride on, and was a big 500 single.  I'm a big time dirtbiker and wanted the bike to have a lot of "dirt" influence.

Some how I managed to lose the "before" picture...maybe I was in too big a hurry to strip it all down.  Here is a picture for reference...complete with with big goofy 23" front wheel.  I stripped the bike down and swapped on a complete honda CR front end and laced a 19" wheel onto the CR hub.


Offline cascade_crawler

  • Posts: 10
Re: 81 Honda XL500 Scrambler
« Reply #1 on: Jun 15, 2016, 18:26:05 »
Next up was the cut off the ugly factory subframe and build up a new hoop. After that I made some supports that would hold the seat pan, and built a pan that would cover the goofy tank mount.  Im not much of a seat guy so I had a local shop build one off of my pan.

Offline cascade_crawler

  • Posts: 10
Re: 81 Honda XL500 Scrambler
« Reply #2 on: Jun 15, 2016, 18:31:58 »
I swapped out the factory shocks for some progressive suspension units and lowered the front fork about 4".  The back end got a rebuild and powdercoated wheel and hub along with SS spokes and a fat rear tire.


Offline cascade_crawler

  • Posts: 10
Re: 81 Honda XL500 Scrambler
« Reply #3 on: Jun 15, 2016, 18:38:34 »
Exhaust fab.  1.25 into 1.75 with a cone engineering muffler.  This thing is loud!

Offline cascade_crawler

  • Posts: 10
Re: 81 Honda XL500 Scrambler
« Reply #4 on: Jun 15, 2016, 18:44:09 »
Everything got stripped down for powercoat and I started assembly and wiring.  I ditched the battery and ran the bike straight off the stator.  Although originally a 6v bike it was pretty easy to swap everything over to 12v using a 12v regulator.  This bike is totally stripped down and only runs a trail tech speedo, headlight and tail light.

Offline cascade_crawler

  • Posts: 10
Re: 81 Honda XL500 Scrambler
« Reply #5 on: Jun 15, 2016, 19:05:08 »
finished and on the road
« Last Edit: Jun 15, 2016, 22:08:20 by cascade_crawler »

Offline coyote13

  • Posts: 1197
Re: 81 Honda XL500 Scrambler
« Reply #6 on: Jun 15, 2016, 19:57:39 »
Abso-freaking-lutely dude
Half the fun's in the get there...

Offline Eleganten

  • Posts: 116
Re: 81 Honda XL500 Scrambler
« Reply #7 on: Jun 16, 2016, 09:29:46 »
Great work!


Sent from my iPhone using Tapatalk

Offline JustinLonghorn

  • DTT SUPPORTER
  • *
  • Posts: 6520
  • No Purple Hearts, No Blue Ribbons
Re: 81 Honda XL500 Scrambler
« Reply #8 on: Jun 16, 2016, 10:12:49 »
Purrdy!
I'm going to eat your brains and gain your knowledge.

Into The Sunset, CB750 build

TT500 the Animal

Offline NoRiders

  • Posts: 702
Re: 81 Honda XL500 Scrambler
« Reply #9 on: Jun 16, 2016, 10:39:01 »
You'd not think it was the same bike...good job, although I'd worry about the dirt getting to the air filter.