Honda XR500R-1984 Reviving

[Ivanych]

Hi!
My name is Ivan. I'm from Russia. (St. Petersburg)

SORRY! My English is very bad. My assistant - Google translator.

I just became the owner of the bike HONDA XR500R 1984 (PE03).
I like the old bikes, and I am satisfied with your purchase. I have a lot of work to prepare it for my future big trips.
I've heard legends about the reliability of HONDA XR, and I want to be sure of it.
HONDA in Russia than when it did not sell motorcycles and XR XR500R is a very rare bike. Bike ran 33000 km. and I think he is in good condition. (I hope. ). The previous owner lived very far away from me, and I could not see the motorcycle in the living only photos and video.

I have a service manual XR500R-83 and Clymer Honda XL / XR 500-600, 1979-1990
But I have a lot of questions and hope for the assistance of experienced and respected members of this forum.
Here are some photos.

[Ivanych]

Another picture

[Ivanych]

Another picture

[Ghost_Mutant]

Good luck with your XR project. The 500 looks to be in good condition

Here is a not so recent photo of my 84:


I also have an 83 XR5, it's behind the 84 in the above photo. The 83 was purchased as a parts bike with yet another 84. Here is how the 83 was when I picked it up:


There are plenty of big bore RFVC XR guys on this forum, and most of them have more respect than I do , but I'll also share my experience and answer any questions if I can.

There are some parts that are getting hard to find for the 500s. Pistons, rings, and connecting rods are unique to the 83/4. Thankfully many of the other engine parts are shared with the 600s, so you can still get a new cam timing chain.

I wonder if parts for the old 500 are easier to find in Europe?

[Ivanych]

Welcome Ghost_Mutant!
I have read many of your posts and got a lot of useful to them.
In Europe, many XR600R, XL600RM (LM) they're popular. On EBAY in Europe are selling a lot of new spending items, but a little old (the former in the past).

[Ivanych]

I could not see bike in to check your motorcycle before purchasing.
Here's what I saw when the bike came to me:
1. All the above were in place.
2. No major damage.
3. No oil leaks and corrosion.
4. Entire frame.
5. Front and rear shock absorbers are working.
6. Chain, star, slipper and slider are worn out.
7. Electrics in poor condition.
8. Generator is about 120-150 watt., 3 outputs, one output is blown (broken)
9. Big Buck 12 liters (3,2 gal), plastic.
10. Rear wheel bearing bad (beating).
11. Bearing front wheel is good.
12. Wheels and tires are good.
While I'm pleased.
I will investigate further!

[Ivanych]

Stator is about 120-150 watt., 3 outputs, one output is blown (broken)

[Ivanych]

Exhaust port.
Large soot.

[Ivanych]

Input port.
Looks good! (I think)

[Ivanych]

insulator cab

[Ghost_Mutant]

Originally Posted by Ivanych

Input port.
Looks good! (I think)

If you are not burning oil and the compression is good then I'd leave the top end as it is. I suppose it may be possible to replace the valve stem seals without removing the head by using the air compressor trick through the spark plug hole, but my engines needed top end work so I did it the traditional way with a C clamp to compress the valve springs after removing the head.

Check the cam chain for alignment/wear. I had three used chains and all three were stretched. A new chain does allow the alignment marks to be perfectly level with the top of the head surface.

My 84 burned a little oil, which is why I started my main rebuild. I had a ton of buildup on my right intake valve from oil getting through the reed valve hole. My valve cover gasket was leaking both internally and externally. However, my left intake valve was perfectly clean, so I'm convinced my oil burning came from the reed valve hole.

I don't see the reed valve holes in your intake ports. So your head may be the first time I've seen an RFVC XR500R without the reed valve. That's good. Honda's manual says they made them that way, but both of my 84 heads have the reed valve and ports.

My engine ran good, but the piston and rings were worn past the limits when I had things apart to measure. How much work do you want to do to freshen up the engine?

Our XRs do not have street lighting from Honda. My stock stators have one lighting coil rated for 55 watts. No battery.

Do you have a battery?

[Blakebird]

I had an '82 XR500R, my first XR and the most comfortable

How easy are parts to get? If you can source oem Honda engine parts without too much difficulty or expense....and are looking at this as a project to get back into top mechanical condition - then I'd jump in.

If parts are expensive and hard to find, then ride it until it won't go anymore They're a fun bike to restore, but fun=easy to find parts.

That wiring is quite a tangle

It's always cool to see what's available in other markets - in the U.S. we got XL's as our street legal versions, all the XR-R's were offroad only with minimal stator output.

[Ghost_Mutant]

Before I forget again, the adjustment knob for the external reservoir is missing from your photos. Parts #26, 24, 25, 23, and 29

[Ivanych]

This bike was brought from Germany, he was an electrician for general roads (light, turn signals and stop). Battery no.
The last owner drove 9000 km. without repair (his words).
But I see that the repair was great.
Spare parts not in stock in Russia, only the filter, oil lamps, chain, spark plug.
All parts for repair only to order from Europe, Japan and the U.S..
Parts for old XR only from the U.S. (In Europe and Japan, little details and they are very expensive). Ships from the USA 4-5 weeks.

Near St. Petersburg is the largest lake in Europe - Ladoga (Laderzhskoe Lake) and Republic of Karelia (federal subject of Russia)
Karelia - beautiful nature, very few people, lots of forests, granite cliffs, and many lakes.

Here are some links:
http://en.wikipedia.org/wiki/Lake_Ladoga
http://www.laatokka.info/photos/_all_laatokka.html
http://www.vottovaara.ru/seminar/galery/exped1.html
Ladoga is a popular place for OFF ROUD - http://www.youtube.com/watch?v=Z5Azq..._order&list=UL

I traveled a lot (hiking in the woods with a tent, hiking) in these places when I was young (a teenager). I want to revisit these places. This is not a sport, just travel.

My plan - fully upgrade the engine by next summer for my travels.
I should be confident in my engine.

[Ivanych]

I continue to study the engine.
Withdrew RIGHT CRANKCASE CARPET /
Oil filter dirty (black and flakes).
Grid - filter clean. That's good.
cam chain and CRANKCASE - touch (there are traces)
Oil seal CRANKSHAFT looks like a dry (hard). I think need to be replaced.
Overall it looks good.
Your opinion?
Additional gasket under CYLINDERS!
Alien (NOT ORIGINAL) Piston???