XS500 Build

[cegan09]

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)

[cheu_f50]

Nice. Mine looks worse than when it started

[cegan09]

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.

[jjm4life]

Get this back on the road!

[mthaynes]

can you delete the indicators?

might look a little more streamlined with them gone

[cegan09]

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.

[FrenchBenz]

Nice thread and good looking bike. I've got a thing for those older bikes. Looking forward to the progress!

[mthaynes]

I can and plan on changing them. The rears are obnoxious.

Glad to hear that

[cegan09]

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.

[nperkins]

They don't make an adapter of sorts?

[cegan09]

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.

[cegan09]

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.

[jjm4life]

Progress is nice. Looks like you'll be riding by fall... 2015. Get on your horse already

[cegan09]

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.

[cheu_f50]

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.

[jjm4life]

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

[cegan09]

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.

[cegan09]

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.

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