The XL500 thread

Discussion in 'Thumpers' started by mtn500, May 20, 2008.

  1. redprimo

    redprimo Been here awhile

    Joined:
    Jul 9, 2011
    Oddometer:
    694
    Location:
    central coast of California
    I have an 80 xl500s and when I think of 60' era desert sleds the tank on my bike does not come to mind. Here is a link to an 80's era desert sled with what looks to me like an elsinore tank. https://picasaweb.google.com/lh/photo/J3oVji_uR4iHRw_DFey_86mgQTuZ1xJ2_CaqaVAtoqg
    Anther option would be a tank from a 305 scrambler.

    Dual high pipes, one on each side would also be a nice touch.
    #41
  2. Rensen

    Rensen Adventurer

    Joined:
    Nov 11, 2012
    Oddometer:
    47
    Location:
    Munich
    Oldschool:clap
    #42
  3. snake89

    snake89 Been here awhile

    Joined:
    Dec 4, 2008
    Oddometer:
    702
    Location:
    Memphis, Tn. unfortunately
    Well, everybodys got different taste. I just like the look of a 82 tank, i have some others in mind as well. Dual pipes are being considered and gonna go with a 19 inch front wheel. Need to get a 18 inch on the rear and run trials tires. Gonna be fun on the street or dirt.
    #43
  4. mtn500

    mtn500 bush jumper

    Joined:
    Sep 13, 2006
    Oddometer:
    301
    Location:
    Floyd, VA, Edenton, NC
    Has anyone used the services of Megacycle Cams (http://www.megacyclecams.com) to install a needle bearing cam on a ruined cylinder head? I've got a smoked cylinder head and cover and would like to repair it for a spare...

    Thanks
    #44
  5. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,897
    Location:
    Eureka, Ca.
    I've never had them do a needle bearing conversion but I have bought several performance cams and hardwelded rockers from them over the years. They've provided excellent service. :thumb
    #45
  6. xrcrasher

    xrcrasher Adventurer

    Joined:
    Aug 21, 2013
    Oddometer:
    93
    Location:
    Portland OR
    [​IMG]

    did it show up?
    #46
  7. xrcrasher

    xrcrasher Adventurer

    Joined:
    Aug 21, 2013
    Oddometer:
    93
    Location:
    Portland OR
    [​IMG]
    #47
  8. xrcrasher

    xrcrasher Adventurer

    Joined:
    Aug 21, 2013
    Oddometer:
    93
    Location:
    Portland OR
    [​IMG]

    im getting anywhere:lol3
    #48
  9. B.Mauser

    B.Mauser Adventurer

    Joined:
    Jun 10, 2013
    Oddometer:
    15
    Location:
    Fort Lupton Colorado
    It worked. Nice bike! :thumb
    #49
  10. brucifer

    brucifer Long timer

    Joined:
    Nov 27, 2007
    Oddometer:
    2,897
    Location:
    Eureka, Ca.
    Yeah, nice '82. :thumb
    #50
  11. chewy500

    chewy500 Thumpin' around

    Joined:
    Sep 21, 2013
    Oddometer:
    2
    Location:
    South Dakota
    [​IMG]
    Uploaded with ImageShack.us

    Here's my 80'. Just took it out for it's first run and it ran great!
    #51
  12. razor8250

    razor8250 lost adventurer

    Joined:
    Mar 16, 2013
    Oddometer:
    81
    Location:
    Louisville ky
    this is what it looked like last week[​IMG]
    #52
  13. Crazywill

    Crazywill probably lost

    Joined:
    Jun 29, 2011
    Oddometer:
    6
    Location:
    Montpeculiar Vermont
    Heres my 79' New rear shocks, swapped the front end for newer KTM components. she runs great and hits the trails better than ever, but part of me does miss having that wagon wheel out front! threw a before shot in there too.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
    #53
  14. Crazywill

    Crazywill probably lost

    Joined:
    Jun 29, 2011
    Oddometer:
    6
    Location:
    Montpeculiar Vermont
  15. Slojoe

    Slojoe Easily Amused

    Joined:
    Jan 21, 2008
    Oddometer:
    499
    Location:
    Albuquerque NM
    #55
  16. xrcrasher

    xrcrasher Adventurer

    Joined:
    Aug 21, 2013
    Oddometer:
    93
    Location:
    Portland OR
    #56
  17. Crazywill

    Crazywill probably lost

    Joined:
    Jun 29, 2011
    Oddometer:
    6
    Location:
    Montpeculiar Vermont
    So yes, the front end swap. I found some KTM forks on e-bay, The ktm's have been using the same forks for a bunch of years across allot of their models, so there was a nice number of potential parts on the e-bay. for reference the forks were tagged: (Forks Triple Tree KTM 125 200 250 450 SX EXC MXC 03 04 05 06 07 08 09 10). once all the donner parts were taken care of, ie wheel, handle bar, brake assy etc. it was a matter of figuring out how to match up a bearing size with the XL's head tube and the new KTM steering head shaft (or modified version there of) i put the info on the bearings on the bottom, at the time i think they were labeled as for use on an old cl350... the aluminum ktm head shaft had to be machined down to meet the new inner diameter of the bearings. I also had to create a collar to bring back the material lost to slide the upper bearing in, so that the top triple tree could clamp back down to the shaft. It was a bit of a trick requiring a lathe and some patience. the other complication is that the head shaft has an offset (i presume so that the handlebars stay straight when the race bikes are on those stands??) this meant that the bearings sit on an axis .070 off from the axis that the triple trees mount. so the shaft had to be machined on two different axis. the only other thing i can remember doing is adding a spacer on the bottom to keep the weight of the bike on the bottom bearing. otherwise the the bottom triple tree would bottom out on the head tube.

    hopefully some of that makes some kind of sence, i took some pictures but not nearly enough!

    http://s786.photobucket.com/user/crazywillis/media/0413131519c_zpsea529c5a.jpg.html








    http://www.allamericanktm.com/All-B...ail.htm?productId=8820890&ez=22-2029&pos=2#/0

    part number 22-2029 SIZE UPPER: 26x48.5x15, SIZE LOWER: 27x48.5x18 - Steering Head Bearings
    #57
  18. xrcrasher

    xrcrasher Adventurer

    Joined:
    Aug 21, 2013
    Oddometer:
    93
    Location:
    Portland OR
    I ve seen that the early CR 500 upside down shocks mount in without any rework

    Check this project I found on the web

    http://mikesbasketcase.wordpress.com/

    You get the idea in the , onthe XR platform, ( same frame anyway):muutt
    #58
  19. Crazywill

    Crazywill probably lost

    Joined:
    Jun 29, 2011
    Oddometer:
    6
    Location:
    Montpeculiar Vermont
    pffft, whats the fun in that? (-;
    #59
  20. dynodave

    dynodave Been here awhile

    Joined:
    Oct 23, 2007
    Oddometer:
    157
    Here's mine. Great wheelie machine!!!

    [​IMG]

    [​IMG]

    [​IMG]
    #60