Honda XR500R-1984 Reviving

Discussion in 'Thumpers' started by Ivanych, Apr 24, 2011.

  1. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    Hi guys!
    I got a good (correct) a sleeve 92 mm after 3 months of waiting.
    But I have a lot of complaints about the seller. Seller -ATVUNLIMITED!!!!!

    Beware, the seller is dishonest. (Liar)

    My purchase was WISECO sleeve, but I have another sleeve again. I asked a question the of exchange: have you WISECO sleeve? His answer was: Yes ​​I have this product!
    This WISECO sleeve:ddog:dog:dog:

    Attached Files:

  2. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
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    Hi guys!
    My project has reached bottom.
    The bike is completely disassembled.
    I should only move up (pop up) now.
    I have a very large list of parts needed to upgrade the engine.
    I have a lot of new parts, the motor in my garage right now::happay
    1. oil pump
    2. Crankshaft bearings and balancer.
    3. Gearbox bearings.
    4. Gear 2 speeds (16 teeth).
    5. A lot of gears and shafts (very good condition)
    6. All seals and gaskets rubber ring motor from the bottom.
    7. spring and Kick detail.
    8. Oil and air filter.
    9. 2 new ARM B, VALVE ROCKER (in the way in parcel )
    10. Cylinder jacket, sleeve, WISECO piston .

    I need a new cylinder head parts (valves, chain, tensioner ... ..).
    This is the second stage of procurement of parts.
    Now it is very good prices on parts. Buying is slow, but I want to have a lot of new parts in my engine.:lol3
    I should have everything you need before spring.
  3. Helmet_Hair

    Helmet_Hair Been here awhile

    Joined:
    Aug 17, 2007
    Oddometer:
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    Seattle
    I think the LA sleeve is equal in quality to the Wiseco product and it will still play nicely with your new piston.:D

    I hope all goes smoothly from here. Carefully inspect everything before buying anything else for the bike. These projects have a way of costing more than expected. In the end, you'll have a bike so familiar to you, you'll understand every burp and fart it makes and know what it means.:rofl
  4. Ivanych

    Ivanych Ivanych

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    <!--[if !mso]> <style> v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} </style> <![endif]--><!--[if gte mso 9]><xml> <w:WordDocument> <w:View>Normal</w:View> <w:Zoom>0</w:Zoom> <w:punctuationKerning/> <w:ValidateAgainstSchemas/> <w:SaveIfXMLInvalid>false</w:SaveIfXMLInvalid> <w:IgnoreMixedContent>false</w:IgnoreMixedContent> <w:AlwaysShowPlaceholderText>false</w:AlwaysShowPlaceholderText> <w:Compatibility> <w:BreakWrappedTables/> <w:SnapToGridInCell/> <w:WrapTextWithPunct/> <w:UseAsianBreakRules/> <w:DontGrowAutofit/> </w:Compatibility> <w:BrowserLevel>MicrosoftInternetExplorer4</w:BrowserLevel> </w:WordDocument> </xml><![endif]--><!--[if gte mso 9]><xml> <w:LatentStyles DefLockedState="false" LatentStyleCount="156"> </w:LatentStyles> </xml><![endif]--><!--[if gte mso 10]> <style> /* Style Definitions */ table.MsoNormalTable {mso-style-name:"&#1054;&#1073;&#1099;&#1095;&#1085;&#1072;&#1103; &#1090;&#1072;&#1073;&#1083;&#1080;&#1094;&#1072;"; mso-tstyle-rowband-size:0; mso-tstyle-colband-size:0; mso-style-noshow:yes; mso-style-parent:""; mso-padding-alt:0cm 5.4pt 0cm 5.4pt; mso-para-margin:0cm; mso-para-margin-bottom:.0001pt; mso-pagination:widow-orphan; font-size:10.0pt; font-family:"Times New Roman"; mso-ansi-language:#0400; mso-fareast-language:#0400; mso-bidi-language:#0400;} </style> <![endif]--> Thank you for your support!
    I look forward to the reputation of the LA sleeve.
    I'm hoping for a good job of that part, too.
    My indignation belong to the seller, he lied to me twice.:ddog
    Sleeves have similar dimensions.
    The old liner was cracked (I have not seen it before).

    Attached Files:

  5. brucifer

    brucifer Long timer

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    Eureka, Ca.
    Ivan, your lying seller aside, don't be concerned with LA Sleeve. They have very good products.
    My machinest is very particular and he uses LA Sleeve all the time.

    Looking forward to seeing your bike go back together.

    Oh, and you certainly have some beautiful buildings in your city.
  6. okeydokey

    okeydokey Adventurer

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    Derbyshire (UK)
    Just a passing thought as i have a busy head and thought of this thread.......just wondering if this has a head off an XL600 fitted? The one i've just stripped looks the same as this but cant find any cast codes at mo.
    I thought the same as you Ghost_Mutant.....didn't think it was at this year??
  7. Ghost_Mutant

    Ghost_Mutant looking for bionics

    Joined:
    Aug 12, 2009
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    border of granite & flats

    Well, Honda did say in the 83/4 manual that the 84s didn't have the reed valve. There must have been some point in the production run where the changeover happened. I was thinking that early 84s had the reed valve to use up excess inventory before the change actually occurred. I do know that my 84 engines have an 84 serial number stamped in the case. At one time I thought that perhaps previous owners swapped out the head for 83 versions. However, I've seen plenty of 84 listed heads on eBay that had the reed valve.

    Since I last wrote in this thread I've acquired another mystery 84/5 head. Not sure which engine it came off of yet, but it looks like Ivan's without the reed valve. Its not an XL6 head since the early XL6s have a special decomp system that uses a fifth valve. The fifth valve opens up to the chamber on the left side of the head which was plumbed/machined. The XR500s and the early XR600s have that chamber but its just empty space with no passageway back to the extra valve.

    Newer machines do not have the chamber or the special spot between the intake valves where the fifth valve sits.

    I will have to measure the combustion chamber size and compare with my known heads to determine if the mystery head is from an XR5. Honda also changed the intake port diameters. The early 83 and 84 heads have larger ports, or at least all of my heads have the larger sized intakes.

    If your head is from an 84, then it should have the cross port carb boot. That allows removing and plugging the reed valve. 83s do not have the cross port in the carb boot. It just so happens that my particular 84s have both the reed valve and the cross port carb/intake boot. It doesn't hurt anything to have both, but I wanted my reed valve ports plugged to prevent burning oil in case of a valve cover leak.
  8. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    Hi guys!
    Spring has come! :clap
    Come heat and to begin the great work.
    This winter I spent at the computer a lot of time and I have a lot of new information about my bike now.
    My mountain of new OEM components become large and I have almost all the details to update my motor.:rofl
    [​IMG]
    New OEM HONDA parts for my bike:
    1. bearings: crankshaft balancing shaft, gearbox, clutch, and the camshaft.
    2. gaskets and o-rings:
    - gasket engine crankcase, a cover of the generator, the right engine cover, cylinder, cylinder head, shaft seals, oil pump, oil hoses, seals for the intake pipe
    3. details of the mechanism cam:
    -
    chain, chain tensioner, motion, guide,valve, oil scraper caps,
    4. The oil pump,
    5. the gears and shafts transmission (used, but in good condition), the new gears 2 transmission XR650L,
    6. The pulse generator, ignition coil, generator (I'm waiting)
    7. oil cooler XR400

    I have:
    CRF450r - front forks, the front wheel and the brake cylinder
    [​IMG]
    [​IMG]
    XR650l - rear swingarm, rear brake mechanism (cylinders, reservoir, pedal)
    [​IMG]
    [​IMG]
    XR600r - rear wheel

    I have to make the welding work on the frame for installation of rear brake before painting.

  9. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    My friend has provided assistance in the adaptation of the CRF steering stem for XR500r and the brake system. He made mechanical processing of CRF axis for XR bearings, made the transition sleeve (sleeve), and the hub to the brake pedal.:freaky
    [​IMG]
    [​IMG]
    Do fitting!!!
    [​IMG]

    All connected!!!!!!!
    I am satisfied with the!!!!!!!
  10. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    Fitting the radiator, the lock will be removed.
    [​IMG]
    swing arm XR650l and frame XR500r
    [​IMG]
    arm, rod assy
    and axles
    [​IMG]
    [​IMG]
    the length of the different

    [​IMG]
    The combination of parts xr650l and xr500 requires manual mechanical completion.
    [​IMG]
    [​IMG]




  11. brucifer

    brucifer Long timer

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    Looking good, Ivan! Your friend looks real happy. :lol3
  12. Ivanych

    Ivanych Ivanych

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    Jan 24, 2011
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    St. Petersburg. Russia
    A long working day and unexpected photography.:wink:

    MR. BRUCIFER,
    I'm walking in your footsteps!
  13. Ghost_Mutant

    Ghost_Mutant looking for bionics

    Joined:
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    Oddometer:
    727
    Location:
    border of granite & flats
    Since I'm planning on updating my 84 with the same modifications, you can tell me how it gets done!:clap

    Looking forward to seeing the final result.:D
  14. Ivanych

    Ivanych Ivanych

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    Oddometer:
    248
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    St. Petersburg. Russia
    The expected Result should be something like this :
    [​IMG]:D
  15. Ivanych

    Ivanych Ivanych

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    Oddometer:
    248
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    St. Petersburg. Russia
    Worked as a welder today.:norton
    Were welded Parts rear brake to the frame.
    I don't have the sample frame with hydraulic brake for comparison.
    And I spent a lot of time on the fitting and adjustment.
    Looks good (I think):lol3
    [​IMG]
    [​IMG]
    [​IMG]
  16. Ivanych

    Ivanych Ivanych

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    Location:
    St. Petersburg. Russia
  17. mikejohn

    mikejohn Long timer

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    1,730
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    Nashville TN
    Some people should not lay a hand on bikes, I was going over my XL and took a look at the battery, a freakin' 6 volt was in there, from the previous owner, got a new 12 volt today, waiting now on some wheel bearings ordered from bike bandit
  18. Ivanych

    Ivanych Ivanych

    Joined:
    Jan 24, 2011
    Oddometer:
    248
    Location:
    St. Petersburg. Russia
    Hey guys!
    I got all of my new transmission today.
    This is part of Honda FMX650 2008 from Germany. They have an excellent condition and I am very pleased with it.
    I will use this transmission in my XR500R.

    [​IMG]

    My new transmission:
    PRIMARY - 70/31 XR500R either 70/32 XR/XL600 I'll be able to choose :evil
    GEAR Ratio1 - 32/12
    GEAR Ratio2 - 28/16
    GEAR Ratio3 - 25/20
    GEAR Ratio4 - 23/23
    GEAR Ratio5 - 20/25

    [​IMG]

    YO-HO!!!!!
    These gears will work, I'm sure now!!:clap

    I have to buy a NEW XR600R-2000 23220-MN9-980 COUNTERSHAFT and some thin washers, and I can assemble the transmission.:D

    Important Note:
    1th
    gear (32) FMX650 different (it has a larger diameter) from the 1th gear (32) xr500r!!!!

    [​IMG]
  19. Ghost_Mutant

    Ghost_Mutant looking for bionics

    Joined:
    Aug 12, 2009
    Oddometer:
    727
    Location:
    border of granite & flats
    :clap Thanks for the info Ivan.

    I'm glad you confirmed that the newer FMX transmission would fit in the old XR5.

    Obviously you need the XR600 shaft for the kick starter. But can you tell me more about the thin washers (shims)? Were you missing those parts from the FMX650 tranny?

    Keep at it, there is still lots of riding season left this year:D
  20. RED1

    RED1 Been here awhile

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    The High Country, Vic, OZ
    You should have gotten a 600R or 650L frame, engine would fit! But not as much fun modifying :lol3