1976 Yamaha XS500 cafe project...Nearly Road Ready!!!

Re: 1976 Yamaha XS500 Cafe project...On to paint!

hey thanks guys! yeah, the mismatching will start to occur as i get going here, the front brake thing is bugging me, only because i know i really want a front brake, and dont feel comfortable rocking only a rear. if i had super clean spoked wheels i wouldnt be so heart broke to rock just a rear, but a mag definitely needs a brake on it of some sort! i did a half assed cleaning of the front brake caliper, the piston was siezed, but wd40 and steel wool cleaned it up in a snap. the piston moves, its a little tough to move it, but its sealed completely no problem at all. the piston was in great shape other than it being frozen from dried fluid. i cleaned the gaskets and stuff and it seems to be ok, i just need a properly working lever and resevoir and i think ill be good. other than that i may need a rebuild if i get a new lever setup and the brake still sticks. we will see for sure!
 
Re: 1976 Yamaha XS500 Cafe project...On to paint!

i would think if the piston is lil sticky now you might just want to rebuild it . a rebuild kit is not to bad around 25.00 and done . and with running a front brake you want one ! the front brake has more stopping power then the back and everyone is diff, but i use way more front brake then rear .
 
Re: 1976 Yamaha XS500 Cafe project...On to paint!

oh, no doubt the front brake is always better! my wing has linked braking for the from and rear with the rear brake, and the front brake activates just one of the front calipers. i always use both, rarely do i just use one of them.

i found rebuild kits for the master cylinder on the front and a rebuild kit. rebuild for the caliper is 30 some od' bucks. the master cylinder rebuild is like 25 bucks shipped. might as well do both while they are off :\ ill order it up in the next couple weeks some time. i have some other stuff i gotta get for this thing, more diamond plate to make my own sidecovers, and some seat foam and stuff for a seat im going to attempt to make...again. lol.
 
Re: 1976 Yamaha XS500 Cafe project...On to paint!

well today was different, instead of build stuff i shifted the shop space around and went picking at a salvage yard! maine cycle warehouse is huge, its in an old building complex. covered with parts of course. scored HUGE on some stuff too. here is my day in order:




First off, i woke the fuck up.




Second off, i went to the maine cycle warehouse and scored some gnarly stuff. Got a set of pipes, a tail light/plate light combo light, a service manual, parts manual, and original owners manual for my exact year bike!!! (nixing the service manual, its for a tx500, but screw it same thing!) now for the picture-fest:


IMG_20111028_140153.jpg



found these pipes that are a little rusted, and the inlets a little large, but fuckit! just cut the flange thingy a little bit and jam it on the doodle thingy at the end of the exhaust and BOOM! exhaust!


IMG_20111028_140037.jpg



a parts list with full schematics and shit! so great!!!!


IMG_20111028_140048.jpg



service manual for a tx500/a, same bike pretty much, it will help me get the basics down if i run into any issues at least!


IMG_20111028_140022.jpg



and this...the gold of my finds...an original 1976 xs500c owners manual!!! BOOYAA!!! i found this at the bottom of a box. couldnt believe it. the cover was missing when i found it, so i flipped through it and saw shit i recognized, and at the top of the page..."1976 XS500C Owners Manual" i was like...INSTABONER!!!! (but it was said in that unreal tournament video game epic voice, that is real low and dark sounding)


which led me to this:


IMG_20111028_140153.jpg



mufflers!!! WOOT!!! the inlet is a little big, but im cutting the flange thingy a little more so i can force clamp it on to fit...shit'll work perfectly!!! hope they sound good! it will definitely tone down the loudness!!!


than the checkout counter (if you even want to call it that ha..half broken bar table is more like it!) i found this:


IMG_20111028_140112.jpg



Brand New too!!! emgo taillight/plate light combo! 15 bucks! had to have it!


IMG_20111028_140010.jpg



thats the blinker setup im going to run, on all 4 points. it looks kinda cheesy, but it gets the job done until i wish to change it!




i had fun doing a little shopping for things, i got just what i needed, and more than what i really wanted with those manuals to be honest, but it was worth the 80 bucks. at least if i get caught in a rut with something, i wont have a problem fixing it! i know for a fact that i have some stuff i can make some money on with the stuff that i took off the bike. i know i dont want to really keep it, so i think ill bring it in if i need something else and maybe do a little trading for some shit.


when i got back i test fit some things and the tail light will work mint, i scoped out blinker locations and have them figured out. ill drill holes on my headlight mount and mount the front ones on either side, and ill cut some diamond plate brackets out for the rear blinkers so i can attach them to the rear suspension area.


another idea that i had for a seat:


IMG_20111028_135949.jpg



an old license plate. but definitely not a maine one, thats just one my girlfriends father has on the wall in his garage. from 1933 to, he insisted i use it for my project. its from his grandfathers old ford. to be honest, i wouldnt want to use it. and heres why. a legit 1933 old maine license plate, has to be worth a little bit of money. and for some slimeball kid to come and steal it off my bike, would be pretty gay. and because i live in the portland area of maine, and scumbags all over the place dont give a charlies-dick about anybody elses stuff, im going to go another route:


z_kochi_55ro5968_400.jpg



an old 1970's era japanese license plate as the seat. ill try to find one with 1976 tags, as thats the year of my bike, and it would be KILLER! screw it, when i get tired of riding on solid steel, ill find myself a seat. fuckit. i love the idea. haters gonna hate anyways, but i love it!


next week, im plating the bike up, and riding the fuggin thing to work. its plated from the kid i got it from until next year, so ill ride like a cute school kid and sit pretty on a snazzy, rear brake only bike, and enjoy it even though it will be cold as fuck out.


here is what i did at the end of my "Garage" session:


IMG_20111028_135934.jpg



thats where my old work area was, all my shit was scattered right in that 15x7 spot.


IMG_20111028_135942.jpg



thats where it is now. my girlfriends mom threw a piss fit i guess due to me not asking her specifically if it was ok to use one side of the garage to work on this steel mule art piece. well before i even did this i asked her dad and he was all for it, shit, he was excited for me. so today i moved it all to the OTHER side of the garage, and now i bet shes going to be all miss happy pants about it. my girlfriend was pissed at me too because i didnt ask her mom. i got kinda pissed. i asked her dad, so he made the call, and he said it was cool. sure, i had stuff scattered everywhere, but it was neatly scattered. so, i now shifted it in front of her dads work bench, which is fine with me. keeps me a little more organized, and hey, i still have a space to work on this thing, so im thankfull for that!




thats all i have for this update. my next session will be:


- zip tie license plate to frame as a seat (until jap one is ordered from flee-bay)
- mount blinkers and make brackets and shit.
- Make new plate bracket with room for rear tail light


secondary objective:

- Bring fuel line from my house to replace worn out lines on carbs
- get fucking fuel filters. whoever lined the fuel shit didnt put filters in...dickheads i tell ya'!




any tips or anything, shoot em at me! and as always, keep following along!!!!
 
Re: 1976 Yamaha XS500 cafe project...JAPanese LOVE!

thanks man! came out shitty after the clear coat, but the point is across with the rising sun for sure ;D
 
Re: 1976 Yamaha XS500 cafe project...JAPanese LOVE!

lol right. hows the seat comming? im gunna be doing some along the lines of what ur doing on my kz750. need all the help and ideas i can get.lol
 
Re: 1976 Yamaha XS500 cafe project...JAPanese LOVE!

well, i ditched my seat idea. what im going to do for now (only because it interests me at the moment, im sure after i order it and get it on ill change my mind and waste more money!) is use a license plate as a seat. like. a fk'n car license plate. idc about how hard or comfortable it is. im just going to wire tie velcro it on and BAM! gnar seat! im ordering a japanese retro plate that SHOULD be just right after i bang away at the edges enough and roll it flat and stuff. if not, my girlfriends dad has a SHIT load of maine plates from other vehicles that would work plenty fine for me!
 
Re: 1976 Yamaha XS500 cafe project...JAPanese LOVE!

today was a bit slow with things. but it was also 32 degrees in the shop im working in. so fk' it. welcome to winter. total bull shit btw. snow and its not even fuckin turkey day yet. shit, not even fuckin halloween. it better go away this week some time. because this dickhead is riding this damn bike next week! todays bike-a-thon garage time went like this:

strapped a seat on:

IMG_20111029_141230.jpg


made a new bracket for my tail light:

IMG_20111029_141153.jpg


and nig rigged a ground for said light:

IMG_20111029_141210.jpg


BOOM! got my light and seat taken care of, next thing is blinkers, chopping the rest of the seat area off, and riding the thing hopefully next week to work! we will see how that one goes. i may just stay around town, grab lunch with it or something, take a trip around the lake. ill figure it out. maybe if i can start it up and shit and see that its reliable, ill most likely ride it to work. work is about 20 miles away. it will be a good shake down ride, if you want to even call it that anyways!

ill be mounting pipes up on monday. ill use make a gasket and some getto clamps to keep it on, make a bracket so the exhaust dont fall off, and BOOM! street legal and running bike will be in order!

i was re thinking my seat idea, and over the winter time im going to definitely buy a fiberglass cafe seat. the license plate will just be a quick fix until i get something real and legit. the seat foam will be some 3m foam with sticky shit on one side. shit will work like a damn charm i tell ya!


Next garage session:

- mount fuckin blinkers
- chop unused hunk of metal off the rear seat area
- ride fuckin bike!

Secondary objective:
- Tighten chain
- Get fuel filters for newly aquired fuel line
- top off rear brake fluid (this should be a primary thing, but fuckit, who needs brakes?)
 
Re: 1976 Yamaha XS500 cafe project...JAPanese LOVE!

AWWWEEE YEAAAA!


today was pimp. cut off the tail section of the frame where the seat is:

IMG_20111031_125047.jpg


got the measurements before hand for a cafe seat for another thread up in this biatch, then i zip tied a license plate to the frame to cover my battery and shiz. alike' so:

IMG_20111031_125041.jpg


then i got some blinkers on:

IMG_20111031_125057.jpg


shitty pic, whatev though, anyways. that is what i accomplished today, my buddy helping me decided to royally fuck up the blinker for the front right side of the bike (only putting this in here because i KNOW it will piss him off 8) it really wasnt his fault at all. the first time the wire came off, it was a little bit his fault, but thats because the wires are small as fuck and if you rotate them in any way they snap off, so he didnt know any better, and the second time i totally have to take the blame. i made him take the blinker off, even though there is an electrical problem that is there and i was un-knownst of it. either way...fuck it ha.). so now i have an electrical issue to figure out later tonight when i go over to my girlfriends place, or tomorrow morning if she decides to wake me up or not. i want to figure it out because i kind of want to take it for a ride and see how it rolls, but i dont want to get pulled over for driving the thing illegally either. fuckit though, up and down the road wont hurt.


tomorrow i need to get fuel filters, adjust the chain, charge the battery, make fenders up, and BOOM im all set to rip! and gas too, that might help a little bit also. not much is left to get it on the road. OH, and i want to get a small push button so i can wire up my start button to work again. i want to have it wired up to the ground, and run the wire from the ground near where i have my ignition at. just something to help get the bike started without kicking the piss shit out of it. in other words, im lazy. but no other people other than xs500 owners know what its like to kick this thing over. i guess xs500's where known to have kick start issues. not that they would fail, but physically its hard to kick start. im not a weak little bitch either, so kicking shit over isnt a problem. anyways, enough of the rant. down to business:


Next Garage session:

- Blinker problem...figure that shit the fuck out
- Fender problem...figure that shit the fuck out
- Start button nig rig problem...wire that shit the fuck up
- chain problem...adjust that shit the fuck up
- fuel filter problem...buy two of them, not one, not three. but two. douche.
- rear brake fluid...top it off...shit looks dry up in that resevoir shit.

- Exhaust problem...mount that shit up!


above is all primary shit that i need to accomplish tomorrow/wednesday. my goal is to ride it to work either tomorrow evening or wednesday afternoon. either way, if it gets to late tomorrow, im not gunna rush that shit, gunna make sure i at least do that shit right so i dont mess it up. last thing i want is for something to fail and for me to flying ass over tea kettle onto the road. ill be ATGATT of course for the first major ride.

oh, and btw, to that dude that wanted me to measure shit near the tail section, i posted it on your thread. i better get a discount if you make these seats happen ;) bitch i want one!

Later!
 
today i took it for a fun spin. was pretty fun. rear brake only, but whatever. my blinkers dont blink, they stay on. which leads me to believe that my relay is at fault for this, mainly because the bulbs are smaller and newer, the new relay probably doesnt want to work right and latch and shit. ill find one tomorrow and see if its the culprit.

got the mufflers on:

IMG_20111101_142041.jpg


clamped, but whatever. had the sidecovers on it:

IMG_20111101_142002.jpg


than had the girl sit on it:

IMG_20111101_144618.jpg


and made a small vid:

http://s937.photobucket.com/albums/ad216/kb1oju/?action=view&current=VID_20111101_144735.mp4


either way, the bike runs and shit. just have to figure out a few small quirks. im going to find some cheap liability insurance online, and buy some, just for the sake of it as its un insured. its plated till next year, just need an insurance card to follow suit.



tomorrows plans:

fill brake reservoir for the rear
tighten chain
fix blinker issue
fenders

done.
 
anytime man! not a problem! ide be stoked to see you make some of these things, ide love to be the first to buy one if you do!
 
road the bike to work tonight, shit was mint. got a thumbs up from a dude in a ford focus, was pretty cool. the bike is a little loud, but thats not a problem, i could make baffles or some shit if i needed too. its nimble, and the blinkers dont work yet, they come on solid, but dont blink.


no pictures today or anything, but i know what it needs:

a headlight bracket (to keep it straight and not move)
front brake still (not a big deal, but ill get it done)
mirrors (oh yeah, ha, forgot about those!)
new chain and sprocket (not NEEDED but should be considered)
paint side covers/polish
change oil AND FILTER!!!
new throttle cable (noticed it was fraying pretty bad when i was tearing shit apart)
paint or polish valve cover
tail section (cafe seat definitely, DCC or airtech)
FENDERS!! holy fuck i need these things haha!! (front one will have a pedestrian cutter, rear one will be like the deus harley cafe racer!)
TIRES! firestone deluxe champions!
blinker relay!!!


thats all i got for today, now it will sit throughout the winter time and be an on going project! glad to have it in a running state though!

done.
 
i know i asked this in the passed, but because this is now the winter project, ide like to make a few good changes too it to make it run right. new carbs. what should i run? i was looking at running a single carb setup if i could, but idk of anyone that makes a log manifold to work this out, or even running two delorto's or whatever, the ones that dont have jets or some shit. thatd be dope too. any thoughts on this?
 
The carbs with no jets are called Lektrons, or Quiksilvers. The easiest carbs to run on the 500 would probably be Mikuni VM30's or 32's. They're simple, not too expensive, and easy to get.
 
mikuni vm32's it is, i remember now bringing this up in previous postings. i think all i would have to swap out are main jet sizes and thats about it. i want to run pod filters as originally planned, tired of doing things half assed!

im getting my turbo'd suzuki sx4 back on the road within this week or the next, so thats my main focus financially. tired of driving a big truck. gas blows compared to the zuk!
 
Okay, that's funny... I have a championship-level Suzuki SX4 autocross car. (Mine isn't turbo, but whatever...) Did somebody clone me, or what?
 
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