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Thread: XS500 Build

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  1. #1 Default XS500 Build 
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    I started a thread a while ago, and then never did anything with it. So lets try again. Time to get the Yamaha XS500 back to riding condition.

    This is what it looked like when I picked it up back in 2009


    I've done very little to it visually since I got it, i'm actually happy with how it looks overall, just have a few tweaks I'll make over time. I did get the frame powder coated a couple years ago.




    Eventually i'm going to get it repainted. I like the blue (which is not original) and will probably just paint it the same color.


    Mechanically it's never ran right. The stock carbs do not work without the stock airbox and that's long gone. I finally ordered new carbs.



    List of items to complete this year on the bike
    - charging system overhaul
    - Brake system overhaul (rebuild calipers, new lines, see if new pads exist anywhere)
    - New chain
    - Start looking at making custom rear sets
    - custom seat (same look, just an inch or two lower)
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
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  2. #2 Default  
    Nice. Mine looks worse than when it started
    Oh Yeah!
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  3. #3 Default  
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    First hurdle is going to be the new carbs, which showed up today.



    The mounting system for these is very different. The stock carbs had rubber boots that bolted to the engine and the carbs slipped into. The new ones have a mounting flange. Current plan is to get a set of adapters made. Initial mock up below. Need to finalize dimensions and clean it up so that it looks better.




    Second challenge is the stock carbs use a single throttle cable. The new ones need one per carb. So I need to find a y cable or cable splitter. Final challenge will be tuning them in on my engine since as far as I can tell no one else has installed these on this bike yet.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  4. #4 Default  
    Get this back on the road!
    Bath salts and dick pills
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  5. #5 Default  
    can you delete the indicators?

    might look a little more streamlined with them gone
    I am not a 14 year old girl, but I play one on the internet.

    Who was the first person to look at a cow and say 'I don't know what these dangly things are, but I am going to yank on them and drink whatever comes out.'
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  6. #6 Default  
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    Quote Originally Posted by mthaynes View Post
    can you delete the indicators?

    might look a little more streamlined with them gone
    I can and plan on changing them. The rears are obnoxious.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  7. #7 Default  
    Nice thread and good looking bike. I've got a thing for those older bikes. Looking forward to the progress!
    1999 C43 AMG: E55 18' Monos, K&N filters, H&R Sport springs, Bilstein Sport schocks, Full LED interior, LED License plate, 8k HIDs head/fog lights, 10mm spacers, resonator + 2 sec. cats deleted, AMG license plate cover, AMG flat hood badge, matte black front grill, AMG pedals, 35% tint, yellow calipers, CF door pins, SS brake lines, Hawk HPS pads.
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  8. #8 Default  
    Quote Originally Posted by cegan09 View Post
    I can and plan on changing them. The rears are obnoxious.
    Glad to hear that
    I am not a 14 year old girl, but I play one on the internet.

    Who was the first person to look at a cow and say 'I don't know what these dangly things are, but I am going to yank on them and drink whatever comes out.'
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  9. #9 Default  
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    Updated the carb adapters and sent it to one local machine shop for quote. Going to drop the models off at a second shop tomorrow.


    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  10. #10 Default  
    They don't make an adapter of sorts?
    Quote Originally Posted by cegan09 View Post
    brass isn't good enough for those guys. Too heavy. They have burnt titanium because they are that awesome.
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  11. #11 Default  
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    Quote Originally Posted by nperkins View Post
    They don't make an adapter of sorts?
    not that i've found. They make them for the XS650, but the engine block side is different from my bike. As far as i can tell, no one has put this style carb on my bike before.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  12. #12 Default  
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    From the dead!

    I have my new carbs, the 2 into 1 throttle cable, and a simplified carb adapter design. I just ordered a 12"x12" sheet of 1/2" thick aluminum from which to make adapters. Tomorrow I'm visiting a local place called make it labs, which is a membership place that has tons of tools. They have a plasma cutter. I'm going to make sure they can cut the aluminum. It will be ugly, but i can clean up the cut surfaces by hand.

    Plan is to cut 4 pieces, and use two per carb to make 1" adapters for the new carbs. Should be cutting them next week.


    every machine shop quoted me $80/each for the adapters. Which isn't unreasonable, but if I can make them myself, why not.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  13. #13 Default  
    Progress is nice. Looks like you'll be riding by fall... 2015. Get on your horse already
    Bath salts and dick pills
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  14. #14 Default  
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    If tomorrow goes well I'll be riding the bike next week.


    I need to sort out how to add an oil cooler. And what I want to do for brake upgrades. I need modern brakes, the old ones are terrible.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  15. #15 Default  
    Quote Originally Posted by jjm4life View Post
    Progress is nice. Looks like you'll be riding by fall... 2015. Get on your horse already
    thats better than my XS850. at this rate, my bike is ready to ride in 2085.
    Oh Yeah!
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  16. #16 Default  
    Quote Originally Posted by cegan09 View Post
    If tomorrow goes well I'll be riding the bike next week.


    I need to sort out how to add an oil cooler. And what I want to do for brake upgrades. I need modern brakes, the old ones are terrible.
    Oil cooler right in front. Mines hidden between the frame.
    image.jpg
    Bath salts and dick pills
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  17. #17 Default  
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    Location isn't the issue. Figuring out how to tap the oil system is. Not much space around the oil filter to add a sandwich plate.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  18. #18 Default  
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    Retaught myself CAM software so I could write the machine code to cut my adapters this weekend. About ready to output it. Just need to get signed off to use the CNC mill at the local shop and I'm good to go cutting parts.



    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

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