82 XL500R merged with a 98 XR400R

Discussion in 'Thumpers' started by Switchblade315, Jul 30, 2011.

  1. Switchblade315

    Switchblade315 Long timer

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    there's a few answers to this. and if you look through he pictures you'll see the XR4 motor sitting on the work bench completely put back together. So I'll answer a few questions as to why I'm doing this.

    the XR was going to be my new DS bike. I got it cheep in boxes. and missing a oil cooler. I now have every part here. I built fixed the problem with the motor but in rebuilding it I found 5 bolts striped. one head stud and 4 valve cover bolts. I had robed the headlight and needle from it for the Old XL at this point. Also I don't have a tittle on the XR and we don't know what state it first came from. I got it from a guy in FL. and they couldn't find any info on it with that state. Now I could ge a bonded tittle but I don't feel like it. so I have a dirtbike that's in pieces with a motor that i need to pull completely back down to fix 5 striped bolt holes and i can't get a tag for it regardless. Nope not going to happen. I'll keep it for parts and I'll find a XR4 I can DS and have a lot of good parts for it.

    So i have my Old XL. I ride it. I love it, but it's out dated. I can't find front brake shoes and it needs them. Humm i wonder if the XR front will fit. so i look the bearings up and they are the same. so I do a little looking at the two bikes. Yes putting the 500 motor in teh 400 frame crosed my mind, but the 500 is a lot bigger. see the 500 is also the bottom part of the frame. and it's not a dry sump motor. the 400 is. won't work.

    So now I'm on the making one cool XL500R. the fate of the 400 is probably going to be cut up to make my one wheeled trailer later on. I think that covers the whys. At this point I could sale the bottom end of the XR and some of the other parts i don't need and I would only have $1150 in my Old XL. As it sits if you include what i've spent on the XR I'm up to $1500.

    Like I said. I'm broke. i have the two bikes sitting here. I've spent $26 on this conversion so far and after i buy a new tire a mount for my mirror and a brake light switch I'll have about $120 in it. i could cut that down if I swapped the tire from the XL rim to the XR rim but it's at 50% ware so I might as well replace it.

    Also i have a KTM200MXC so i don't need the XR for a dirtbike. It took me 6 months to decide to do this. I've looked at the XR for a year, and I've tinkered with it and bought things for it all along the way.

    in the end I wanted to do something cool. this is what I came up with.:evil
    #21
  2. Switchblade315

    Switchblade315 Long timer

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    well i got the steering stop fineshed today and mounted. even adding a cool little add on peace. one more bracket to finish tonight and all that will be left is the mirror mount, brake light switch and a tire.

    here be the pics.

    I for got to tell the guys at the welding shop exactly how the thing was suppose to be made and when i first test fit it, it wouldn't work. so a little of this.

    [​IMG]

    and then a test fit.

    [​IMG]

    well that isn't going to work the tabs are in the wrong place, so i cut teh welds and headed over to my dads shop to weld them back on in the right place.

    I came back to my shop and test fit it again. needs some more grinding to fit. it was hitting the stop in the frame so I had to grind the arch out some more.

    Well two days of grinding welding grinding drilling holes welding some more then more grinding. test fit and boom got it. a little pant and I have this.

    [​IMG]

    time to mount and test.

    [​IMG]

    perfection

    [​IMG]

    now looking at this i got a idea... I have a extra KTM part i need to do something with. what to do.... :evil

    [​IMG]

    that is how she sits for now. more to come.
    #22
  3. Switchblade315

    Switchblade315 Long timer

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    I was have a good day today until the prick at work causes problems and pissed off my cover man. It's takes me 3 years to get a cover guy. and they treat him like shit. but that's no surprise because they do the same to me. Now this isn't my boss it's other employees. My boss is great. anyway i just needed to get that out. here's a update pic. i'll get a few more later.

    I got the top mount finished today. and got everything mounted up. the only thing that has a problem is my wires, they refuse to go back into the holder, and the choke. I'm going to have to relocate it. I'll fix that later. here's a shot from the front with the headlight just hug there because I've got to make sure I've got it wired right. wires are the same color on the bulb side..

    So here it be.

    [​IMG]
    #23
  4. biggurn

    biggurn Yes, it is BIG.

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    Looking great!
    #24
  5. Switchblade315

    Switchblade315 Long timer

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    Thanks. and if anyone wants to know that brace is off my KTM. I changed to a newer stile fender that it would not work with. I had to put a newer brace on that bike to match the fender on it so I've had that brace laying around my shop for a few years now. It's the stock brace off a 98 KTM200MXC :evil

    I'm going to work on all the wires tomorrow since it refuses to go where it is suppose to go. and I may just take that silver box off the front as well. it wont serve any purpose anymore. Hopeing to get a tire on it tomorrow and give it a try. And see how hard it's going to be to get the forks adjusted.
    #25
  6. Switchblade315

    Switchblade315 Long timer

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    well I went out today and taped up the wiring, mounted the light, moved the hand guards, put a few zip ties on it. I sat on it and it feels.... different. I'm looking forward to try it out.

    so I pushed it back so i could get a better shot of it. All that is left to do is put a tire on it and try it out.

    [​IMG]
    #26
  7. Switchblade315

    Switchblade315 Long timer

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    the front end swap is done. i have not road it yet. I will post a report when i do that and I get some outside shots when i do. it feels a little stiff just sitting on it and pushing down on the forks with the brake locked. But that's a good thing because the old forks where way soft. i haven't turned the clickers to see where they are set I'll do that before I ride it.

    so what y'all have been waiting to see is here, have a look.

    [​IMG]

    [​IMG]

    and to compare, before

    [​IMG]
    #27
  8. Pigford

    Pigford British

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    North Dorset, UK
    Great bike, had one last year (XL500R) but sold it and got an XR400RY

    Nice to see the old bike being used- but you gotta get rid of that horrid aftermarket headlight thing & put the other one back on :evil
    #28
  9. Switchblade315

    Switchblade315 Long timer

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    heck no.. pant it maybe. but i can see at night with that headlight and the number plate throws the air up just enough I can ware my off road helmet with out it trying to remove my head.

    I've been thinking of panting it but i haven't settled on a color yet.
    #29
  10. Switchblade315

    Switchblade315 Long timer

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    ok since the ugly headlight has been pointed out. I've been toying with the idea of panting it since I put it on there. what do y'all think of this idea.

    [​IMG]

    from this.

    [​IMG]
    #30
  11. Trophy1298

    Trophy1298 Vicarious Cowboy

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    or just paint it black. Either will look better than the white.

    Looks like a fun project. I have been toying with the idea of putting YZ426 forks on the BMW. I am sick of replacing seals. They go out about every 3000 miles. The YZ fix is what many have done. Have to be resprung for the havier bike and a few plates and such fabbed up.
    #31
  12. Switchblade315

    Switchblade315 Long timer

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    mine really wasn't that hard. getting the plates made and right was the worst part if I would of had the tools to cut the mettle here it would of been easier. and a welder. having to go else where to drill cut and weld the brackets was a pain because i didn't have the bike there to test fit.
    #32
  13. Switchblade315

    Switchblade315 Long timer

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    I got the pant today .. i forgot to get the bonding agent.. I'll do that tomorrow. :evil
    #33
  14. Switchblade315

    Switchblade315 Long timer

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    first ride out on the Old XL with eh XR forks.. felt good except for a wobble on gravel. I'm not talking head shake i mean a wobble. no I thought maybe it's the tire i used so i hit the highway.. nothing, it was as smooth as could be. so no way it's the tire or rim. going to jack it back up and look at that again anyway. I think it's just sitting higher in the front then it did and that is causing it. I'll lower it some if I see no warp in the tire and rim. and OH MY GOD what a front brake. :clap oh and it has no wobble on pavement wile on the brake ether I think it's just sitting to high.
    #34
  15. luckychucky

    luckychucky Long timer

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    It looks good, I'm liking your fairing. If I ever find a local XR with disc, then I too may try this. Good job.
    #35
  16. bighaasfly

    bighaasfly Something to shoot for

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    My buddy had a '82 XL500. Rode the snot out of it for years. The previous owner had seized the motor when he forgot to add oil after an oil change. He let it cool down, added the missing oil and sure enough it broke lose and started! He sold it to my friend who rode it for years afterward, never having investigated the previously seized motor. My friend sold it to a third party (by now it was largely held together with bailing wire and 2 part epoxy) and I believe it is still chugging around our home town with somebody to this day!! Great bike and will be a loyal companion no doubt!
    #36
  17. Switchblade315

    Switchblade315 Long timer

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    yeah the swap was easy. And once i figure out what is causing the wobble it will be great. it felt really good every where else. the front was a lot firmer but it ate the bumps nicely. I'm also going to check the sag I never checkd it before because it just worked where it was. I'll get it set up and let y'all know who it works out. I'm going back to work this week so my time to work on my bike just got cut big time.
    #37
  18. Switchblade315

    Switchblade315 Long timer

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    the first color is on.

    [​IMG]
    #38
  19. High Country Herb

    High Country Herb Adventure Connoiseur

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    Your bike is looking great!

    I agree with the colors for the fairing. It might look more "factory" if you stick with a square panel of black above the headlight, somewhat like a 1983 XL600R. When you do the black, you may want to touch up the side plates at the same time. It would really bring a restored look to the bike.
    #39
  20. Switchblade315

    Switchblade315 Long timer

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    yeah I'm trying to find some black backgrounds to redo those. I haven't located any yet. I really don't want to pant those.
    #40