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Old 01-07-2011, 08:25 PM   #16
Ghost_Mutant
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Quote:
Originally Posted by AlpinaE24 View Post
Does the 84 have a plastic tank? Damn i want an old XR
Yes, the tank is plastic and holds just over 3 gallons, largest factory tank on a XR from Honda I believe.
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Old 01-07-2011, 08:54 PM   #17
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front fork bushings on damper rod forks

Quote:
Originally Posted by mcma111 View Post
Replacing the bushings is a piece of cake. Just like replacing fork seals, pull the fork tubes out of the lower sliders and there are 2 bushings on the fork tube. One floats and the other sits in a notch. The one in the notch will require a slight pry to open it so you can slide it off the tube and the other one will slide off behind it. Duck soup.
Hi Steve,

I'll take another look at the spare fork tubes/sliders in the attic, but I can tell you that I did take one upper bushing out of a spare slider when I was last working on the forks (this slider had the worst bushing wear). As far as I can tell, the bushings on this early 43 mm fork sliders (damper rods) are pressed in placed. Note that I say the bushings are in the slider part, they don't come out with the tube. There are no notches in my tubes for retaining bushings.

Here is a pair of photos I took at that time:

This slider has the worst bushing wear. That black fuzzy stuff is detached teflon. The seal has already been removed. What you see in the photo from top to bottom is:
-upper teflon coated bushing
-spacer tube
-lower teflon coated bushing (about 3x the area of the upper bushing)

These three parts don't show up in the parts fiche as separate items. I don't think Honda intended them to be replaced. The parts fiche just shows the fork slider itself as an assembly. Very expensive, and I'm not sure if they were discontinued years ago.

I modified one of my cheap slide hammer/pullers to extract the upper bushing, after which the spacer tube came out easily. I couldn't reach the lower bushing with any of my tools and I then gave up the idea of replacing the bushings. I have two extra sets of XR500 43 mm forks, so like I said earlier I just matched up the best 4 sliders I could find. Those are on the bikes now.
Here is a photo after removal of the upper bushing:

You can see the small upper bushing and the spacer tube below my slide puller makeshift tool. The spring/rubber band mod kept the puller jaws spread wide so it would engage the very thin upper bushing. Not much room to grab the lip on these parts. The file was used to sharpen my puller jaws so they didn't slip.

I finally got some smarts and realized that I needed to swap in newer forks that have the replacable bushings you are talking about. I've managed to locate two cheap sets of XRL forks, but now I have to deal with the front axle and wheel bearings. I don't have those parts yet, and I put the XRL forks in the attic for the winter. My plan now is to finish up the bikes in March and get them on the road. After that I'll look into rebuilding the XRL forks and swapping front axles.

Of course, in the meantime I'm still looking for the parts I want to add/mod the bike with, such as the FMX gearing, oil cooler, tank level sight glass, etc.

I mentioned this bushing problem I had in Bruce's thread because I don't think he has the same option to just swap in newer forks into the 81 XR500R since they are not 43 mm tubes. If there is scratches on the fork tubes, then it's likely that the bushings are worn and I don't yet know how to replace them
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Old 01-08-2011, 04:41 AM   #18
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Good info on the forks there GM.

I'd also like to say to anyone viewing this thread, if you have or have had an XR500 of any year, please feel free to post up pics or information or,,,,whatever.
I don't believe there's an XR500 thread yet so this could be that thread.
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Old 01-08-2011, 06:53 AM   #19
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I was going by past fork work and looking at the parts fich #8 fork tube bottom has a notch for #13

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Old 01-08-2011, 07:27 AM   #20
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Ah, very good. Bruce is all set then. Just one more thing that is different on my early RFVC XR5.

I just looked at the fiche at cheapcycle, which is where I think your diagram is from. That fiche has a mistake in that it lists the front shock for the years 81-83. I have the 83 and it's not like that. It's like the 84 fiche at cheapcycle here:

No notch, and no bush shown, which in this case is a bad deal

Looked at the 85 XR600 fiche, it looks like it has the same setup as my 84 XR5:


Actually, I think the 84 fiche at cheapcycle is for the 83, and I think the 84 XR5 is more like the 85 XR6 fiche. The difference is that the 83 had a few more parts in the seal section than the 84. I did not reuse those extra parts, or the 83 sliders, both my bikes have 84 sliders on them now. However there is still a difference in that the XR6 doesn't have the hub protecting plastic part, #22 that bolts to the left slider. My 84 sliders have this plastic piece.

I did put some thought into making a custom tool to extract the bushings from the slider housings, but in the end I realized how much easier it would be to upgrade to cartridge forks
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Old 01-08-2011, 07:33 AM   #21
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Quote:
Originally Posted by brucifer View Post
Good info on the forks there GM.

I'd also like to say to anyone viewing this thread, if you have or have had an XR500 of any year, please feel free to post up pics or information or,,,,whatever.
I don't believe there's an XR500 thread yet so this could be that thread.

I don't know, it sometime feels like I need to start a thread just for the 83-84 models. I keep finding out how different my bikes are from everyone else.
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Old 01-08-2011, 10:03 AM   #22
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Eh? Is it just me?

OR, does the XR500 model seem like a Bastard Stepchild in the thumper world?
My nephew just picked up an '83 model today and by comparison to the DR650 I have it seems to be relatively under appreciated & seldom modified ....
I don't think there are 5 threads for this bike on the interweb total..
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Old 01-08-2011, 10:12 AM   #23
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WOOOHOOO! She runs!


See the new mud on the fender!


Pulled the carb, which involved removing the seat,tank,side covers,rear fender, muffler and partially removing the air box assembly. Then the carb would come out between the shock and frame and out the right side of the bike.
Gave it a good cleaning and installed a 155 main, up from a 152. Reinstalled everything and changed the oil. Tried to clean the air filter but it's rotton. So.... I lightly cleaned what I could and reinstalled it.
I LOOKED at the valve covers but didn't remove them as my impatience was getting the best of me. It has good compression so I figured I'd give it a shot first then go back and adjust the valves later.
Kicked it through a few times to get fuel to the intake, then kicked about 5 times and she lit off....then missed a couple times....then died. Appeared to be electrical related so I tried the easy stuff first. Disconnected the kill switch--same, pulled the plug cap and inspected the resistor,,looked okay, snipped the end off the coil wire a bit--better but still dying. Pulled the plug,,yuck! Stole the plug from my XL600R/XR650L Hybrid engine and installed it--BINGO! Runs great!
She blew blue smoke for a couple minutes then cleared up. Probably valve seals. She hasn't run since 1998.

Anyhow, I'm pretty happy. With the exception of the speedometer, everything works. The engine sounds great. Tight with no mechanical noises. The clutch and transmission work just fine.

Now to order a new air filter and whatever wear items it may need, a valve adjustment and a good cleaning.
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Old 01-08-2011, 11:17 AM   #24
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Thumb cant beat that

When its as easy as a new plug life is good!!
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Old 01-08-2011, 12:05 PM   #25
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Absolutely!
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Old 01-08-2011, 12:18 PM   #26
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Congrats It doesn't look too cold where you are at, so go out and have fun.

Quick question: does your XR500R have a reed valve in the intake, between the carb and head? If so, does it help with the off idle bog? Or is that another one of Honda's weird designs that didn't withstand market testing?
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Old 01-08-2011, 12:22 PM   #27
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Quote:
Originally Posted by VtStrom View Post
OR, does the XR500 model seem like a Bastard Stepchild in the thumper world?
My nephew just picked up an '83 model today and by comparison to the DR650 I have it seems to be relatively under appreciated & seldom modified ....
I don't think there are 5 threads for this bike on the interweb total..
I wouldn't quite describe it that way. These old bikes are pre-interweb

One thing is for sure, you had better be good at junkyard hunting if you end up needing a replacement part. I bought my 84 several years ago for $800, then I found two rolling frames with engines in boxes for another $100. From that the 83 was reborn and I have spares for some things.

I don't need the extra 150 ccs, so I'm happy to save the gas for the trail.
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Old 01-08-2011, 01:50 PM   #28
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Quote:
Originally Posted by Ghost_Mutant View Post
Congrats It doesn't look too cold where you are at, so go out and have fun.

Quick question: does your XR500R have a reed valve in the intake, between the carb and head? If so, does it help with the off idle bog? Or is that another one of Honda's weird designs that didn't withstand market testing?
Thanks man!

Yes, this is a reed valve equipped engine. The '81-'82 XR500R were the only year models with it. Strange the XL500R didn't have it.

Does it work? Maybe. I do know it's pretty hard to stall these bikes in the tight, slow trails. They'll thump right along at a snails pace without fear of a flame out.
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Old 01-08-2011, 10:21 PM   #29
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TT600 carb? Likes of Yamaha 600s!!

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Originally Posted by brucifer View Post
Ghost Mutant, nice RFVC bike.

Ahh man! I would have taken you up on the manual if I didn't buy one off ebay JUST THIS MORNING!
Thank you very much for the offer.

2wheelsgone and Garthe-- Thanks guys.
I have a soft spot for XT500s too.
I see over it TT you try to put a nintga 250 carb on your TT600. Do you get it to work? Nice XR500! Back in day, I rode a lot enduros. There was a honda guy who rode first a XL 350, and then had the XR 500. Won a national enduro on it. Also won the local enduro races too. I am working on my yamaha bikes too. Have 3 TT600s, 1 XT600, 1 XT550. Just need a SRX600 for the complete 600 bikes!! Ride a XS650 on the street to. And for woods riding have a WR400f too. Like a WR450 for the e-start!!! Thump-on! Big ED XT 600 &TT 600 FAN!!
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Old 01-09-2011, 05:42 AM   #30
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Hi Ed! No, I didn't get them to work. I would have had to modify the tank and I'm not into that.
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