The 1976 Yamaha XS500 ground up build

JRK5892 said:
I used a car lamp in mine... like a plasma blue (ish) color, really does well to light up the road!
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Did you have to fit it into the original lamp or is it a whole new assembly? And where did you get it from?
 
it is not a sep unit, it is a round replacement lamp, fit right in... i have however done swaps and gutted the inside of a stock lamp, and JB wlded in the lock tab and ran HID in there before with no issues... you can also look at VW bug lamps, you can get those and swap to H4 bulbs

i got my lamp from orileys for like 8 bucks
 
Do any of you guys have tips for cleaning engine cases? Mine are covered with caked on gunk that is stuck in places I cant get a brush. I've degreased, soaked, scrubbed, and still have a bunch of crap stuck all over my engine.

I've been thinking about driving over to the car wash and just blasting the s--t out of them... unless there are any better suggestions?

Thanks guys.
 
saywhat said:
Do any of you guys have tips for cleaning engine cases? Mine are covered with caked on gunk that is stuck in places I cant get a brush. I've degreased, soaked, scrubbed, and still have a bunch of crap stuck all over my engine.

I've been thinking about driving over to the car wash and just blasting the s--t out of them... unless there are any better suggestions?

Thanks guys.
Click to expand...

I took out the engine. Degreased it. Used tooth brushes, etc. Washed it. Degreased it again with Foaming stuff. Then sandblasted it hardcore. Pressure Sprayer would work too.
 
Worst case scenario, I'll sand blast them. I'm half tempted to just drop them off at the machine shop and pay them to tank them for a few days.
 
You could always soda blast it too.... Get a rental sand blaster and some blasting soda...
 
I used my garden hose yesterday with a nozzle, and it took some of the gunk off. I think I am going to sand blast the remaining crap and hope for the best. I'll try to get some reassembly done over the weekend and update the thread with some more pics.


Cheers :)
 
you going to tear down the motor then? if not hwo are you going to prefent dust and sand from getting in there? sandblasting is not clean it is messy, gets in and on EVERYTHING... i would NEVER do that to a assembled motor, ever... will basicly set it up to be ruined... put in the time. engine cleaners like GUNK, simple green diluted with water, brake cleaner (non clorine), brushes, and rags... can not short cut a clean motor, got to put in the time... blasting it will not be the way to do this motor man. exp with all the crevises and shit that motor has
 
It is fully disassembled right now, just dealing with the bare aluminum cases. I guess I could spend a few more hours with the little wire brushes I have, it just feels never-ending.
 
ooh man then blast away!!! if you do it in a cabinet your going to have to remove all the nasty greace and shit first anyway, cause it will contamidate the media but if you pot blast it it does not matter at all
 
MAKE SURE YOU THOROUGHLY CLEAN EVERY PART OF THAT MOTOR BEFORE REASSEMBLY!!!! Sand and media can get into the oil passages and whatnot and destroy the motor. Soda blasting is the way to go, as oil will break down any left over particles.
 
and in case you missed it ...

The starter chain is Honda !?

CHAIN (DK219H-82L)
14410-235-003 (replaces 14410-216-003)

JOINT, CAM CHAIN
14411-216-000

http://hondapeninsula.com/fiche_section_detail.asp?section=120034&category=MOTORCYCLES&make=HONDA&year=1965&fveh=2876

(chain just happens to come from a CB160 (cam chain)

Now the balance chain is a Kawasaki part ?!

Kawasaki 92057-1415 (CHAIN,CAM,BF05-104L)or at last check Tsubaki still makes the BF05 in bulk , you just have to find someone that carries it .
Seems a shame to cut 62 links out of 104 and use the rest for a bracelet ...

Things I do to source parts for my customers :p

The later tensioner for the balancer has a thicker slipper for the starter chain and is a better adjuster for the balance chain . Take a good look while the flywheel is off . I have a fair copy of the parts fiche if needed .

If you find a better way of installing the flywheel/starter clutch/chain gears without dropping the key into the ... than I have please share .
cheesy.gif


~kop
 
Soda may be the way to go, and kopcicle, you just confused the hell out of me haha.

Edit: kopcicle, I'm completely eliminating the starting system, so I don't think I will even run that chain, just the balance shaft chain. Good info, thanks
 
I had everything from the jugs up glass blasted. I assembled those pieces and sealed it up thinking it would keep the media out. I was waaay wrong. That shit got in everywhere, and it wasn't that easy to get out. I cleaned the f@#k out of it and I still got a slight pit in my stomach over it. I wish I never would have done it.
 
agreed exp off the bike man. soak that sucker in engine cleaner... use non clorinated brake cleaner those sucker will clean up in no time!
 
Of course, if the engine is still assembled, and you use baking soda, there's very little chance of doing major damage...
 
I broke down and took the engine cases to get hot tanked to get all the crud off of them and finally got back to work on the bike... Assembled the cases today. You might notice the missing balance shaft. I think I'm going to roll without it, along with the removed starter.

Now I just need to find a tool to hold the clutch boss so that I can torque down that bolt.


driveside.jpg


caseclutch.jpg


Cheers fellas, I might be able to ride it next year haha.
 
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