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Found 5 results

  1. I have a 84 xr500, I have the right crankcase cover off and just wondering if I have to do anything special when putting the cover bank on so the compression release mecinism works properly.
  2. megadillberry

    79 XR500 "Build"

    Hi all, This is my first post on here so hopefully I don't mess it up. Also hope I don't piss of any "purest" people out there as this is in no way a restoration and I have no interest in restoring it to original. This is what I have been working on the last few weeks. I picked up an xr500 about a month ago for $300, it started but had no clutch lever so I didn't get a chance to ride it. I noticed later that it has a White Brothers aluminum swing arm and possibly upgraded shocks but I really don't know. Its pretty rough but a running bike for $300 I wasn't going to complain. I decided i wanted to build it into something that was kind of a cross between a bobber and a scrambler and use it mainly for commuting across town to work, but still be able to tackle mild single track. I went though my garage and was able to come up with a front fender off of a newer honda 150r (i liked how small it was), and a rear fender off of an 04 crf250x so it has the licence plate holder an led brake lights. the front fender bolted directly on but he back took some modifying. From ebay I found a 21" wheel for the front (81-83 xr500) but the drum was a 131mm max dia while the original 23" was a 141mm max dia. this was quite a disappointment but I guess i should have done a little more research. I ended up putting the brake hub from a 83xl250r into it, its not perfect but it works for now. I then started to build a seat, while the original was quite comfy, it did not have the look I was after. I started with cardboard until I had a shape I liked. Then I cut, bent and welded it all together, luckily at work I have access to a nice break, shear, welders and scrap metal. It turned out ok I thought for my first attempt at a seat pan. Next I put some closed cell foam on it from a sleeping pad I got from the sporting goods store. I wanted a low profile for the look so the thickest part is only about an inch thick. I used a steak knife to trim the foam and it worked alright, I ended up covering all the edges with gorilla tape to smooth it out. I then covered it with marine vinyl I found at Jo Ann fabric. Instead of cutting and sewing to get the material to fit right I used a heat gun which stretched the material enough for a "good" fit. I used 3m spray glue and a metal plate on the bottom to secure the cover, its holding so far. Here it is with the seat all finished. I also found some horrendously cheap foot pegs for a yz bike from (99-05), I think they are a cast steel of some sort. I guess you cant complain much for $15. they required a little grinding to fit but seem to work good enough. I was finally able to take it out this last weekend and had a blast, it runs way better than a $300 bike should. I had to remember how to engine break as I usually ride a 2t with good brakes, it turns out they went away from drums for a reason. My seat wasn't quite as bad as I thought it would be out on the single and double track. We also went out to some hill climbs and the 500 impressed me with amount of torque it delivered at any rpm. This bike is much different than anything I've ridden before between its torque and having almost no weight over the back tire. As far as the seating position goes, I actually like how compact it feels. I also think the low profile seat goes with lines of the bike rather well so I'm pretty happy with how it turned out, especially for being my first try at making one. Next for this build I would like to make it street legal. I'm not looking forward to figuring out whats going on with the wiring and converting from 6v to 12 as the components I have are 12v and i would like to have the front light be a LED light bar. I have a different bike that I am thinking about adding lighting to using a rechargeable battery like a Milwaukee m12 or something, so maybe I will go that route. I would also like to figure out an exhaust for this at some point so i don't get kicked out of my neighborhood. Thanks for reading, I'd love to hear what you think and any suggestions you may have.
  3. Taylor R. Boehnlein

    1982 XR500 Help

    Trying to figure out if electrical is working/needs replaced. Generator tested 263 ohms, pulse tested at 99 ohms. Ignition coil primary tested at 1.7 ohms and the secondary at ~60 ohms w/ the spark plug cap. CDI seems to be the issue, but the results almost seem too bad to be true. The only resistance I found was the Green to Black/Red at 147.77x200k ohms, Black/Red to Black/White Kill at 152.2x200k ohms, and Blue/Yellow to Green at 150.1x200k ohms . The OEM manual does say that a specific tester is needed, but that seems like a farce. Any idea what might be going on? CDI's are a little pricey and I would like to not replace unless needed.
  4. Hi all, Will from Melbourne in AUS and I am pleased to finally join ThumperTalk. I'm 9 months into a custom build transplanting an '81 XR500R into a '81 CB250RS and I'd like some advice. I'll start with my question which is a fairly simple one, and then follow up with an answer to some anticipated questions which might help understand what my issue is and what may be causing it. MY QUESTION: Does the CDI box or CDI black box igniter (shindengan) from the CB250 run the XR500? or put in a different way, does the xr500 motor need its original cdi box (which is a round metal box) compared to the rectangular rubber one off the 250, in order to fire? Thanks in advance, Will -break- MY PROBLEM: I can't get the XR500 started, even though it has just had a full-rebuild inc. bore/piston/valves/hydroblast, spark, good fuel, carb-kit, and it was built using torque wrench and some precision around building it which is why I'm surprised it didn't fire straight away. ANSWERS to potential Questions are; 1) What has been blended together between the two bikes? 2) Why on earth am I building a cbxr500rs...? 3) More depth around the issue please? 1) What has been blended together between the two bikes? First off, I used the cb250 wiring loom because it was complete and ready to run the lights which the xr doesn't have. The cb250 & xr500 motors share side covers, and some other parts. Because I want a lighting system and given the XR doesn't have an alternator or wiring for a lighting system, I used the alternator from the 250 which bolted straight into the 500 replacing its original magneto. The Alternator from the 250 is also a bit lighter so it may improve performance. I used the side cover and wiring from the 250 on the same Alternator side for 2 reasons: i) because it was in better condition and, ii) had the wiring plug to go straight into the loom from the 250 as well. A perfect match so it seemed. On the right side, given I had just replaced the pulse-generator wire from the 250 before it died, which cost $100 bucks, and the side cover was once again in better condition (and matched the 500), I used 250 right side cover and its pulse generator on the xr500 which also means it can plug straight into the loom as the xr500 motor had no plug on the end which saved me mucking around. Motor/Running Gear: cb frame & front Yend, xr motor, xr carb, xr rear-wheel to retain ratios, 2 into 1 exhaust from the xr500 which has been custom modified to be 2 into 1 into 4 under the seat! (for looks mostly, although careful attention to pipe diameter taken to retain back pressure and exhaust velocity). The XR500 motor has a new 10.5:1 piston, stage 1 bore to 89.25mm, valve-grind/resit/lap and hydroblast, all new other parts plug/gaskets/oil/seals/carbkit etc etc, xr500 sprocket, weld another row of bars above the frame to accomodate the carb and seat, custom fab on frame/seat etc to accommodate. May make an airbox for it if I think its required. Wiring: cb250 Loom (xr had none), lights etc from the cb250, Regulator Rectifier from the 250 (of course because it is designed for the power of the alternator), but I used the Coil from the 500 motor which is smaller, as the bigger one from 250's was stuffed, Fuses from the 250. *However, I used the CDI box off the 250 (not the 500) because it could plug into the loom, and this is where my question lies? 2) Why on earth am I building a cbxr500rs...? Well, I'm sentimentally attached to the cb250 which I built as a learning project 5 years ago, and I read the xr500 motor fits in the frame and saw someone in the UK which transplanted it I was pretty intrigued. When the cb250 finally died it was a perfect opportunity to hunt for a donor bike and put the xr500 motor in, and also a perfect opportunity to do any modifications/upgrades and servicing to the cb bike which I had originally built on the cheap and now happy to sink money in it. 3) More depth around the firing issue please? It has spark, but won't fire and start even though it seems it really really wants to. Given a fair amount of precision went into building the motor I'm surprised it didn't fire in the first couple of kicks and I've since spent a bit of time trying to get it started to no effect. I'm tempted to check ignition timing using one of those lights, although the one I have is not designed for bikes but cars instead and is a pain the ass to get rigged up!
  5. Jasethekiwiguy

    XR500 Issue pls help

    I have an 1984 XR500 and my friend has a 1983 XR500, we both bought them recently and they both have the same problem..which leads me to think it's a common problem. The bikes start on first, 2nd kick and idle's well...but between about 40% - 60% throttle they bog, (completely bog, pop and bang) then at 70% kicks back into life. I've had the carb out twice...all jets are clean and I replaced the air cut off valve just in case. It's a dual carb, but im beginning to think it's not a carb issue...possibly coil??? Has anyone come across this problem and come up with a fix? Any help or ideas gratefully received!
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