1975 Yamaha XS500B

[topherchris]

My first post about the bike. I picked it up a couple years back for a good price and I’ve been so busy that it’s just been collecting dust ever since. It’s 1975, 14XX original miles, last registered in 1986, I’m the third owner. The bike needs A LOT of TLC. The story I was given by the second owner is the original owner wrecked his bike and bought this one. Some time after he purchased this bike, he developed some health problems, so he didn’t ride much. After he passed, his wife held onto it for a while before selling it in 2017/2018. The second owner had grand plans for a cafe build but had too many projects and decided to sell her.

So here we land in 2020. I too had grand plans for a cafe build, but put it on the back burner for my other projects. I finally started feeling guilty for leaving it sit for so long untouched, my projects started winding down with more time at home, and so I started tearing her down. I know what you’re thinking...you posted in the wrong section of the forum...shortly after I started digging in, my wife and I got news we are expecting our first child. She’s now in the third trimester and I’m buried to my eyes in preps and projects for our first baby, so I’ve made up my mind to complete the tear down and restore because it will be a little less labor and time intensive than going down the path I wanted to. The cafe build will come later.

Now that you know my life story, I’ll let you know I’ve been lurking on this forum for a while, secretly admiring everyone’s project builds. Specifically, this one:
https://www.dotheton.com/index.php?threads/75-yamaha-xs500-cafe-project-open-throttle.14392/

I need some direction and pointers. Where does everyone order OEM parts from for these bikes? Also, can someone with knowledge look at the pictures and let me know if the exhaust on my bike is aftermarket? From what I can tell, it’s supposed to have a pipe on each side and this only has one on the right.

As the bike sits, the forks need to be rebuilt, the front brakes need work (front caliper is locked up, no pressure on lever, and it looks like the master cylinder had a leak that allowed fluid everywhere), the fuel tank needs at a minimum to be cleaned out and I think resealed, the whole thing needs a good deep cleaning (engine, frame, wheels, EVERYTHING), the right side intake cover needs to be replaced due to a crack in it, and all basic maintenance needs to be done (carbs rebuilt, throttle cables replaced, chain replaced, spark plug, air filter, etc.).

I’m working on stripping it down. I found a company that sells service manuals, so I picked one up. My only experience with carb tuning is a two stroke dirt bike, so this will definitely be a learning experience.

 

[topherchris]

More pics before tear down.

 

[goldy]

Yes, please, please restore it...but if you think it's less time consuming and cheaper than doing some sort of a custom, you may be in for a surprise. In any case, its in far, far, far too good a condition to hack up into a cafe project....find something a bit more screwed/ wrecked to do that with. Mechanically, with the mileage being so low, it may only need an oil change, a new battery and a carb cleaning to get it up and running. Don't mess around with the airbox, or filter set up if you have no experience tuning CV carbs. If you need your tank sealed, I recommend Caswells products....it's the only thing I'll use these days and I've tried just about everything on the market. You can get a lot of parts from Mikes XS...and many XS650 parts will fit. Ebay is also an excellent source of bits and pieces. Good luck, keep your eyes on the prise and keep us posted please!

 

[pidjones]

I agree with each of goldy's points.

 

[topherchris]

Yes, please, please restore it...but if you think it's less time consuming and cheaper than doing some sort of a custom, you may be in for a surprise. In any case, its in far, far, far too good a condition to hack up into a cafe project....find something a bit more screwed/ wrecked to do that with. Mechanically, with the mileage being so low, it may only need an oil change, a new battery and a carb cleaning to get it up and running. Don't mess around with the airbox, or filter set up if you have no experience tuning CV carbs. If you need your tank sealed, I recommend Caswells products....it's the only thing I'll use these days and I've tried just about everything on the market. You can get a lot of parts from Mikes XS...and many XS650 parts will fit. Ebay is also an excellent source of bits and pieces. Good luck, keep your eyes on the prise and keep us posted please!

I know it’s going to take a good bit of time and money either way. Cheaper in that I won’t be hacking the frame, ordering custom body work, lights, triple trees for inverted forks, wheels, etc. and because I’m not doing all that it won’t take quite as long. I do like your point with the mileage and condition to not do a cafe build, my going in was “buy an old bike and build a cafe bike” that honestly changed my perspective, it’s a very good point. I appreciate the feedback and I’m going to look into Caswells and Mikes XS.

Quick question...the service manual doesn’t say how to support the bike to remove the forks. I come from the world of sport bikes, so I have stands that assist me in removing the forks on those bikes. My plan was to completely strip it down to bare frame anyway so I can get the frame recoated and clean up the engine then figure out how to remove forks and swing arm. But for future me, do you put it up on the center stand then strap the rear tire to the ground to lift the front or put the frame up on blocks or ...?


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[Jimbonaut]

Such a great looking bike, welcome again to the forum. And welcome in particular to the Restorations section - my current bike's been languishing in here for the last two years so it's always good to have some company! Have you considered maybe a rest-mod? That could be a great compromise, your bike would look killer with a some modern upgrades and a few sensitive changes. Switching out the indicators for some sleeker LEDs, trimming the rear fender and losing the enormous taillight (again, an LED unit would tidy that up), new bars, grips & mirrors, maybe some new instruments and some decent shocks out back - damn that would look nice.

Whatever you decide, have fun making it your own. Ultimately that's all that matters.

 

[topherchris]

Such a great looking bike, welcome again to the forum. And welcome in particular to the Restorations section - my current bike's been languishing in here for the last two years so it's always good to have some company! Have you considered maybe a rest-mod? That could be a great compromise, your bike would look killer with a some modern upgrades and a few sensitive changes. Switching out the indicators for some sleeker LEDs, trimming the rear fender and losing the enormous taillight (again, an LED unit would tidy that up), new bars, grips & mirrors, maybe some new instruments and some decent shocks out back - damn that would look nice.

Whatever you decide, have fun making it your own. Ultimately that's all that matters.

I have considered that, I’m still pretty torn on just how much I want to modify though. One thing that is definitely going to change is the front brake setup. Instead of trying to source new rubber lines I’m going to get a stainless line and use a pressure switch banjo to activate the brake light instead of the block behind the headlight. The handlebar area clutter does bother me a little bit, but it’s one of those


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[topherchris]

Post day 1 tear down.

I was pretty stoked when I found the original tool kit! It’s hard to find a five year old bike with the original tool kit and this one is 45

It took me a minute to figure out how to get the tank and throttle off and the master link is still stuck. The throttle wouldn’t turn when connected to the TBs, so I’m not sure what’s up with that yet. The tank looks like it’s leaking from one of the inner mounts and the inside is corroded pretty bad.

Does anybody have info on a rear disc conversion? I’ve never owned anything with drum brakes, so other than knowing how they work, I have no mechanical experience.

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[goldy]

I know it’s going to take a good bit of time and money either way. Cheaper in that I won’t be hacking the frame, ordering custom body work, lights, triple trees for inverted forks, wheels, etc. and because I’m not doing all that it won’t take quite as long. I do like your point with the mileage and condition to not do a cafe build, my going in was “buy an old bike and build a cafe bike” that honestly changed my perspective, it’s a very good point. I appreciate the feedback and I’m going to look into Caswells and Mikes XS.

Quick question...the service manual doesn’t say how to support the bike to remove the forks. I come from the world of sport bikes, so I have stands that assist me in removing the forks on those bikes. My plan was to completely strip it down to bare frame anyway so I can get the frame recoated and clean up the engine then figure out how to remove forks and swing arm. But for future me, do you put it up on the center stand then strap the rear tire to the ground to lift the front or put the frame up on blocks or ...?


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Before I got a lift, I used to put the machine on the centre stand and block the front of the frame. Once the front wheel is off, the centre of mass usually shifts past the centre stand, so the chance of knocking it off are greatly reduced.

 

[topherchris]

End of day 2. The master link is super stuck. I’m using a piece of wood with a hole in it and a c clamp to try and push it out with no luck. I think I may end up cutting it. I’m pretty much at the point of needing to get the master link off to get the engine out.

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[irk miller]

Don't know much at all about these XS500. That's a cool looking bike.

 

[Maritime]

There are a couple of older threads on here of some folks have built. I know they can crack heads for some reason but are pretty good overall

 

[topherchris]

Thank you, I hope it looks cooler when done The guys talk about the cracked heads in the thread I linked above. I haven’t researched it too much, I plan to deep dive it when I’m in the reassembly phase.


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[Brodie]

Check out Dreadrock's build. He pulled his XS500 from a field and built a beautiful cafe out of it.
Out in a field Build ... XS 500 The Sock Monkey ( Finished pics ,video, )

 

[Maritime]

Yep, Scott's bike is a beaut.