The 1976 Yamaha XS500 ground up build

[two-smoker]

Wow, that turned out great! Let me know how you like running without the balancer- I was thinking of doing the same thing.

 

[johngofast]

Very clean engine! I have a XS360 in the back of my garage and that makes me want to start on it. Excited to see how this project goes!

 

[johngofast]

Whoa, just noticed that you're also in the Salt Lake Valley! Very nice to find someone else on DTT from our area. Let me know if you ever need some help, tools, moral support......

 

[DreadRock]

WOW just found this thread ! very bike man got some great ideas .

 

[saywhat]

Thanks for all the encouragement guys, and yes, good to see people from SLC. So I'm on the home stretch but need an easy way to rivet the new cam chain link, any tips? I tried a few sets of pliers, but I think I might have to go get a mini C-Clamp to press it together or something.

Here's where I'm at now, just need to powdercoat a few covers and get it back in the frame (other than cam link)

 

[saywhat]

Just finished a few covers, coated them in a texture silver similar the color on HD Sportsters... Kind of a raw aluminum look...

 

[JRK5892]

are you going to paint the motor? the 2 silvers clash. i do liek the cases though

 

[saywhat]

Well, got the engine in today, still need to sort out the the points and everything. I kind of like the two tone, but totally understand where you are coming from Joe, I may paint it down the road, just eager to get it running.

 

[JRK5892]

do it now man! now is the best time while you have it torn down. it is winter... will take you 2 days tops to prep and paint it... make all the diff in the world!

 

[saywhat]

Well... after purchasing the bike in boxes I finally got to hear her run today I've got a new set of jets on the way to accommodate the pods and less restrictive exhaust, and a chain so I can actually ride her. Pretty validating hearing her run, and run smooth. I guess all the hard work did pay off.

 

[saywhat]

Now on to the brakes and tank cleaning.

 

[saywhat]

From rough beginnings.... It's almost done, just a few more tweaks, but running strong re-jetted and with the balance shaft removed completely

 

[two-smoker]

Looks good! How do you like it without the balance shaft?

 

[saywhat]

I never rode it with the balance shaft, but it seems to be pretty normal as far as vibration, but I haven't really gone on any long rides yet.

 

[IronSpade]

Alright well I'm a little late to this party but I have a TX500 project going on right now for a client that has been put on the back burner because we found out it needs a new top end. My client is actually considering purchasing a newer bike and we just start over with a different bike and simply sell me the TX for what we have in it so far which really isn't that much.

I need to know if anyone has a source for the top end parts such as piston kits, cam chain, valves (not sure if I need to replace them but it would be good to know if any replacements exist), gasket sets, etc...

Thanks for your help, also Is it the consensus that running the bike without the balancer is the ideal way to go? Mine seems to have a lot of slop in that chain and I'd much rather ditch the starter and giant battery all together and just run a small Lithium-Ion instead. I haven't pulled the top end off yet cause I wasn't sure if the cam chain can be replaced or not.

Again thanks for your help. This what she looks like so far...

 

[JRK5892]

why did you pull the balance shaft out? how is the jetting working out for you

 

[IronSpade]

By the way Yamaha RD400 swinger and forks are a direct fit as well as the wheels. I made the high pipes from sections of 16G J-tubing and cut the mounting flanges from the stock pipes. The fuel tank is from a 1969 Suzuki T305 and I have the chrome panels as well as the rubber knee pads. Its going to look cool.

Talk soon Travis

 

[DreadRock]

The 'swinger' on a RD400 is also about a inch longer then the ones on a TX/XS......

 

[two-smoker]

Damn, that's a good tip! Joe, the balance shaft on these bikes is largely unnecessary. Basically, removing it doesn't seem to affect vibration much, and it's like removing 8 pounds of flywheel mass.

 

[saywhat]

I haven't had any chances to do any plug readings, so not sure on the jetting, but it feels better than it has with the current jet set up. It's a little cold blooded, but will get it more dialed in when the snow melts.