82' Honda XL185s rebuild

Discussion in 'Old's Cool' started by G2mk3, Mar 26, 2009.

  1. G2mk3

    G2mk3 Been here awhile

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    So for quite a while I have avoided the whole motorcycle thing. I always tend to have a few too many hobbies at one time, and i always saw motorcycles as being the straw that would break the camel's back. I graduated college in December, perfect timing to start looking for jobs that don't exist. With no income since June, I haven't been able to feed money into my subaru wrx and golf GTI rally car. Since every time I think about working on those cars the numbers are three, if not four digits, it was time to find a cheap project to keep my hands busy. ahhhh I remember there was a bike tucked away in a barn at my girlfriends parent's hobby farm, it turns out to be a 1982 Honda XL185s, a few questions later I was told that if I got it running he'd sign the title over to me:evil . Here it is in a deep slumber:
    [​IMG]
    pulled it out to blow some of the dust off and get a better assessment of the situtation:
    [​IMG]

    Looks to be mostly there. One of the GF's brothers pulled the lights off a while back to make it look more like a dirt bike, tires are rotted, chain looks bad, seat cover needs to be replaced, fork and bars are a little twisted from being droped... give it a kick over and it's seems to be decent inside :D seems like a good project. In the end I can have a bike that is good enough to cruise around on some county roads for adventures, but more importantly will be a decent first bike as well as being basically the best moped ever for around the cities:super

    Last saturday my friend Brian (captianpegs) and I decided to get it started. Poured the old gas out of the tank, cleaned the carb out and poked a blocked jet out with a needle. with a little starter fluid it fired up and we were able to give it a spin:
    [​IMG]
    The engine seems strong, but both of us were unable to get 5 gears. 0 down and 4 up... looks like all those years as chasing cows as a farm bike took it's toll on 1st gear. We figured it was best to quit running the bike and drop the oil to see what the scoop is:
    [​IMG]

    and so begins the project
    #1
  2. G2mk3

    G2mk3 Been here awhile

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    Tonight I finally mustered up the energy to go pull the engine... WOW is this bike stuff SOOOOO much easier than working on cars. Unbolt the carb, throttle cable, clutch cable, wiring for the ignition, chain, exhaust, 7 bolts for the engine and it practically fell out:
    [​IMG]
    [​IMG]

    We found last weekend that other people claimed the bike to be home for a while:
    [​IMG]
    My cat chairman meow confirmed our hypothisis "where are those mouses! LET ME AT EM'":
    [​IMG]
    #2
  3. G2mk3

    G2mk3 Been here awhile

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    I've already got some gaskets for the carb and a new air filter from Honda, a Keyster carb kit (i've heard good and bad things, so we'll see how it compares to what comes out of the carb) and a factory service manual off of ebay :evil

    I think tomorrow we'll be opening the engine up to see how bad the gearset is and if the metal bits did any damage elsewhere. Any pointers on taking the engine apart would be much appreciated, I've heard of special tools for the clutch... any way to avoid buying that sort of thing? Also, do people ever mess around with the dog teeth on the gears? On the rally cars the conditions of the dogs always made a huge difference, but I'm not sure if they will have such an effect on the small bike transmission.
    #3
  4. captainpegs

    captainpegs Adventurer

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    What do you plan to do with this rocket? Is this a learning experience or do you plan on actually using this moped? Hell, I bet a CM400T could even smoke this thing!!


    :rofl
    #4
  5. G2mk3

    G2mk3 Been here awhile

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    easy now.... thems fight'n words!:kboom
    #5
  6. SimpleSimon

    SimpleSimon Aspiring advrider

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    Check the needle on the Keyster kit and report back! :ear
    #6
  7. DoubleBit

    DoubleBit Been here awhile

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    Ha! Maybe the "captain" just doesn't posess the maturity to enjoy a decent little trail bike.. Hell, there's nothing wrong with a 400t either for that matter..

    Build the little 185, have fun with it..
    Besides, have you ever tried riding a street bike on trails?
    Different bikes, different days, moods, terrains, they all have their strong suits and most can be enjoyed when ridden in their elements by a rider pointed at the proper objective.. Enjoying things for what they are and not being hung up on some power trip..
    #7
  8. dbarale

    dbarale Squiddly slow

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    Naaaw, if you re-read the firt post you'll see that captainpegs is a friend of the OP and is helping with the project. Just trash talk between buddies it seems...
    #8
  9. RallyPoser

    RallyPoser n00b

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    I want to see a pic of the full "Knockout" poster. . . haha looks awesome

    Boxer on a Ferrari?
    #9
  10. DoubleBit

    DoubleBit Been here awhile

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    My bad, just reacting to one of my pet peaves.. There is so much "profiling" in motorcycling, it can ruin the fun..
    #10
  11. G2mk3

    G2mk3 Been here awhile

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    brian: "I guess I don't make a very good noob"
    #11
  12. G2mk3

    G2mk3 Been here awhile

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    Simon, I quick pulled the needles to see if there are any differences, from what i can tell there are none (w/o using a micrometer). If there is a difference it's very small in the profile. I did notice that the original is stamped "60D" and they keyster is stamped "D62".

    [​IMG]
    #12
  13. captainpegs

    captainpegs Adventurer

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    My cover has been blown

    :2guns


    Is there just one clip position on those needles?

    (and that cat would make a NICE hat!)
    #13
  14. SimpleSimon

    SimpleSimon Aspiring advrider

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    Cool. I'm trying to determine if the rumors about Keyster kit needle sizes being off from stock is true.

    Sounds like there is some truth if stock is 60 and you got a 62.
    #14
  15. G2mk3

    G2mk3 Been here awhile

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    yes just one clip position on the needle. i think i'll keep the keyster needle as a spare, but unless i see huge differences i think i'm going to run the jets because i have a hard time trusting how clean i'd be able to get them.
    #15
  16. G2mk3

    G2mk3 Been here awhile

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    and so it began:
    [​IMG]
    first casualty:
    [​IMG]
    second:
    [​IMG]
    The cam bearings don't look new, but after all the metal bits are cleaned out they will be fine (at least long enough for me to get my giggles out of the motor):
    [​IMG]
    [​IMG]
    There sure was a lot of metallic sludge at the bottom of the motor, I'm glad we quit running it when we did, but chances are the bike was used for quite a while in this condition. I quit for the night when I got to the nut holding the clutch pack on, looks like i'll have to fab some sort of tool to get it off tomorrow, any ideas?
    [​IMG]
    #16
  17. anonny

    anonny What could go wrong?

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    Dorkpunch to the white courtesy phone :D

    I have welded key stock to an old socket before.... crude but effective. :evil
    #17
  18. G2mk3

    G2mk3 Been here awhile

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    yeah, I'm thinking some poor socket is gonna get it today
    #18
  19. captainpegs

    captainpegs Adventurer

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    And who's Puthy Willow?

    :oscar
    #19
  20. G2mk3

    G2mk3 Been here awhile

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    Saturday I was fortunate to get some help from my friend (and his huge shop) to get a socket modified for the special nuts on the clutch and crank. I forgot to bring my camera so I didn't get any pics of the the actual tear down... but really most of it was me using the parts washer to clean everything anyway.
    Here is the socket, it looks pretty nasty in the picture but it fits the nut perfectly.
    [​IMG]
    Then I was able to get to the bottom of this no-first-gear nonsense.
    [​IMG]
    Yep. That'd do it alright.

    So now i'm left with a nice pile of clean parts. I picked up a bottom end off of ebay for 65 bucks shipped, my factory service manual arrived and I have a complete gasket set ordered, so hopefully this weekend i'll be able to get the engine back together. Being able to use a parts washer was KEY to getting all the parts back into useable shape. I cleaned my friend's parts washer before I did any of my stuff, every time I'd take a break the bottom was covered in metal flakes. Slowly as I cleaned the bearings became smooth, only one still feels like it has a few nasties in it but overall it's still very good, I think I will just do a few quick oil changes on the bike to let the oil flush the last few bits out. I can't stress how much time it takes to get it all properly clean however, my hands were pretty sore and tingly from using the parts washer for half a day.
    [​IMG]

    Next up is the carb while I wait for the engine bits to arrive.
    #20