XS PROJECT

ooops!

 

Nice job Wiz, as usual. There is a 78 XS500 for sale near me that I would be tempted to bite on, but parts availability scares me off. I could justify getting this bike if it was super cheap ($200 or thereabouts) to replace the XS650 I am (stupidly) selling to my buddy (got to go through with it now, he sold his to buy mine!). I quite like the very simple lines of this old bike, and the 4 valve heads promise a bit more sprightly performance than period twins like a KZ or GS400. I could also justify hacking up a bike that cheap into a bobber, but knowing me, I will spend way too much polishing a turd I can't resell for 1/2 the money I put into it. So what do you say? Parts available? Readily cross-referenced to the 650 at all? XS650 Direct here in Canada had everything I needed for my 650, it would be neat if a lot of that was usable on the 500 as well. Here's a pic of the bike in question:

 

Great looking bike, Mac, that would scrub up a treat, 50 times better than the one I paid 500 smacks for.
The mufflers will be a problem to replace, but I found a pair 'that will do' for $20 on the bay, brake pads are easy & I was lucky to find a master cylinder kit, bay again, the spin on oil filter isn't made any more, I think the local Yamery has found me one from a dealer in receivership, I have also cut the existing spin on in two & gutted it with a dremel, a cartridge from a late Toyota Corolla squeezes in, then a 30mm ring from a 3.25 innertube with silicone sealer & pipe clip holds it all together (I can post pictures if needed) quite a tidy get out.
Overall I am really enjoying working on this old bike, points & all.
This wasn't a popular bike, but if you speak to people that had them, back in the day, you hear nothing but good, like cruising all day at 70 mph no problem, with the air flow of the 8 valves.
Go for it, faint heart & all that. Wiz.

 

Some more progress, carbs, coils, rear mudguard, et al.

 

Wheels painted, headers & mufflers fitted.

 

The rims on this bike are amazing, i thought they looked cool when they were beat up and chipping and even when they were sand blasted. But seeing them like this, all painted and polished, makes me want to go out and buy one of these bikes just to cut it up for a chopper that would have some sweet rims.

 

lookin good! and yes, those rims are sexy

 

New METZELER tyres fitted.....

 

The motor is running, starting on the button ~o)

 

That will be good to hear, congratulations on th rebirth :>

 

very cool... cant wait to see how it turns out

 

Tail fairing fixed, picture shows colour scheme, which is black base coat, with a hint of gold metalic:
BC 768=450
BC 775=453
BC 750=458
With 2 pack clear over.

 

Mrs. Wizard took your blue paint, didn't she

 

Yeh & I still had 12 gallons left (

 

i had 1 of those for a while drove it around town .i fixed it for someone had to drill and rethred the head because spark plug broke off even broke an easy out off in the shell inside the head. to make a long story short the guy didnt want to pay me and wouldnt give me the title .in fla you had to have 1 i ended up letting my buddy have it for parts and the rest he used in his yard for fill it was in the mid 80s at the time i had a built rd400 so didnt have much interest in it. but it was fun to run the dirt roads with i believe it had over 20k on it then . dont think you will find a nicer one when your done thats for sure

 

Thanks for the vote of confidence, Cutlass.

 

Side panels finished, I cut the decals free hand from thin card & the guys at Progress Signs, ran them through the computer & out popped the vinyl, now I have mastered the technique the world is my lobster......

 

you did that from cardboard? wth...

 

Talent, Schooter.

 

Final drive finished (exept for a pin in the castle nut) brake overhauled & new pads fitted.

 

Blimey you've been busy, lookin' very good Wiz'. Should be finished by th end of th financial year then?

 

Don't know, is that the begining or the end of July?

 

Tank finished, that's the last of the painting, just waiting for the fork tubes, to put the front end together.

 

paint looks fantastic. i bet you will have the nicest xs500 out there . whats the next project after this bike ? wouldnt blame you if you just rode the wheels off it for a while

 

nice paint, say hello to your helpers for me

 

Hey Polock, are you trying to get me a D I V O R C E ?

 

no, just a little eye strain

 

Seat pan repaired & ready for re-covering, one flange had to be reconstructed with fibreglass & 4 of the 8 bolts for the seat strap & hinges had to be drilled out & re- tapped.

 

That's coming along a treat wizard

 

Time for a reminder of how things were.

 

drum roll please

 

Here ya go 'T'

 

Seat recovered, I don't know if this is a sign that we are in recession, here, only it's normally a 3 week turnaround, would you believe this one, same day service. 8O

 

Just need some fork tubes.

 

sharp!

 

Finished, just carbs to sync & fine tune.

 

Nicely done Wiz! From scrap to glory in only 4 months, 15 days, 23 hours, and 49 minutes! Well done!!!

Now, Whatcha gonna do with it?

Loren

 

Well Loren, I'll road test it for a bit, make sure it does what it should, then someone else can be the proud owner, leaving space for the next project. Wiz.......

 

Beautiful bike wizard, cant wait to see how that xs650 turns out.

 

Nice work Wiz. Wish you were a bit closer to my home.
I'd love to have you work your magic on my old XJ900.

 

Picture shows the homemade manometer as suggested by Hillsy, I used auto trans' fluid, as it is bright red, you do need serious restrictors otherwise a carb full of fluid will result.
For you guys that have tried this method before, I can get the fluid level at + 2k revs, but at idle they are unequal, is this normal?

 

2 steps forward & 3 back, the cam chain jumped the sprocket & bent all 4 inlet valves.

 

ARGH!!!!! I feel your pain... Had to do an engine swap in my new 900 last weekend due to chain noise

 

THAT SUCKS. I have been there before. I bent a valve on my XJ1100 when doing a valve adjustment. I rolled the engine a little to far when I had a zip-tie holding a intake vavle open. Oh well, grab a cold drink and a smoke, sit back and think why did this happen.

 

Was this because the write up for setting the timing was wrong? (Don't believe everthing you read post)

 

Exactly that, Markie, followed the book instead of my head & look where that got me.
Lucky we have Len (xj4ever) he located some valves for me at a very good price.

 

Try sync-ing the carbs at a higher RPM.

Can't wait to see this bike run !! Keep at it !

 

I wouldn't have given such a flippant reply if i'd known!