XL500S - Restomod

Discussion in 'Some Assembly Required' started by shinyribs, May 12, 2018.

  1. shinyribs

    shinyribs doesn't care

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    Sanding the fins is definitely an option. Always loved that look on choppers, don't see why it wouldn't look good here, too .


    Question and the SuperTrapp muffler. Since the exhaust exits through the discs vs straight out the back, are there any issues with exhaust gases melting fenders? Or throwover soft bags?
    #81
  2. Kai Ju

    Kai Ju Long timer

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    They used to make a deflector shield that would prevent that from happening.

    Seems they still do:

    upload_2018-6-11_11-37-38.png
    #82
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  3. shinyribs

    shinyribs doesn't care

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    Interesting. I guess 120° would do the trick. Point that sucker straight down since there's a fender on one side and a bag on the other. Man, that just seems weird...
    #83
  4. shinyribs

    shinyribs doesn't care

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    A guy on another forum mentioned the height of this bike, and a couple local buddies ( who've never seen the bike in person) were questioning raising the bike. Pics are worth 1,000 words, right? I'm not a small guy and these are not big bikes. It's a big bike heart in a little bike body :D

    Screenshot_2018-06-11-09-11-58.png
    #84
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  5. shinyribs

    shinyribs doesn't care

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    Cush drive showed up today. The 250L cush ends up too wide to fit in the 250R arm ( whooda thunkit), but it worked out easy enough. Realized the seal sits pretty far away from the bearing, so I took some measurements and went to work.

    Turned down the cush hub to leave just enough room to hold the seal.
    [​IMG]


    Turned up the axle spacers. Made the disc side to fit right off, but had to wait til I could measure to shave the sprocket side to final size.

    [​IMG]
    Disc alignment is good.


    [​IMG]
    Then measured for final fit on the sprocket side. Close, but it's all good. Makes me wonder why Honda used a wider arm for the L anyway.


    [​IMG]

    If there's any doubt the chain run was too easy look at that slider lined up with the primary sprocket [​IMG]


    [​IMG]

    Leveled the frame and pulled lines again. Chain run doubled-checked and is still good. Went to see about centering the rim and it's bang-on perfect. Didn't see that coming, but I'll take it! Roller status complete. :gdog

    Kickstand rehab tomorrow evening...
    #85
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  6. shinyribs

    shinyribs doesn't care

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    Totally agree with the first part, and thank you for the second part! I appreciate the kind words.
    #86
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  7. shinyribs

    shinyribs doesn't care

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    Does anyone know for certain what stock gearing is for these bikes, and how big of a counter sprocket can safely fit?
    #87
  8. Kai Ju

    Kai Ju Long timer

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    14/41 is stock, don't know what the biggest C/S sprocket would fit, sorry.
    #88
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  9. shinyribs

    shinyribs doesn't care

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    Thank you!
    #89
  10. MacNoob

    MacNoob piney fresh

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    :lurk

    Love these kinds of projects. Maybe once I retire?

    So if you get a commercial USFS approved spark arrestor, is that sufficient for compliance if you get caught somewhere?
    #90
  11. shinyribs

    shinyribs doesn't care

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    Yes. If you've got a USFS tag you're good to go. That's one reason I'm flip-flopping on a muffler. I think a reverse cone would look alright, but you're not gonna find one with a spark arrestor. I can build one in, but I won't have the USFS tag.

    But don't wait til you retire! Build it now and enjoy it :thumb
    #91
  12. Kai Ju

    Kai Ju Long timer

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    Give Cone Engineering a shout, they might have what you want/need.

    http://www.coneeng.com/motorcycle_components.html
    #92
  13. shinyribs

    shinyribs doesn't care

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    I didn't completely lie about that. I did go turn up an extension for the stand, but I was too lazy to drag the welder out.

    [​IMG]

    And I've been distracted with clearing some new trails lately...too pretty lately not to ride! Got a bike to deliver out of State this weekend and some riding buddies I haven't met up with for a while. Probably put this project on hold for a few weeks while the budget replenishes and I rack up some miles. Love my XR4...ol' Trusty.

    [​IMG]
    #93
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  14. foxtrapper

    foxtrapper Long timer

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    Agree with you. I'm a short rider with an XL500s myself, and I can darn near flat foot it when I'm sitting on the seat.
    #94
  15. freewheelburner

    freewheelburner Been here awhile

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    QS1.


    Sent from my iPhone using Tapatalk
    #95
  16. shinyribs

    shinyribs doesn't care

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    Sorry, I don't understand.
    #96
  17. Kai Ju

    Kai Ju Long timer

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    #97
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  18. shinyribs

    shinyribs doesn't care

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    Ah, I see. Thanks.

    I took a stab in the dark and Googled SuperTrapp QSI and obviously came up blank. :D
    #98
  19. shinyribs

    shinyribs doesn't care

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    Muffler for the XL showed up today. Just a simple EMGO piece, but it's got a removable end cap so I can repack/ play with spark arrestors as needed. I figured this would be an OK setup, but I'm actually pretty pleased with the outcome. Got home with the muffler and ran over to the old shop and found some old bends from building headers. 1.75" was bang on perfect.

    [​IMG]


    This is the whole midpipe to be welded. I cut the small elbow on the right off the u-bend to get started. Things were looking good, so I trimmed the second elbow on the left and stuck it in the muffler. Things were still lining up good, but I had little gap between the two elbows. That little piece between the elbows just happens to be the sole piece of pipe I cut off. Too easy :D Dang ol Honda's are so willing to run they damn near build themselves.


    [​IMG]

    Tidy underneath. No craziness.


    [​IMG]


    Took the spring off the shock to check clearance with the tire at full stuff. No issues.


    [​IMG]

    Curious what the wheel travel would be with the longer arm. Measures out to 8.5" of wheel travel. Not alot by modern dirtbike standards, but pretty average for a dual sport. Exact same wheel travel as the KLR forks, so once again, perfect balance without even trying too hard. I'll take lucky over good any day. [​IMG]


    [​IMG]


    Longer wheelbase does create this problem now ( tire hitting the tag mount), but that can be sorted out easily enough later. Probably gonna ditch this whole lighting assembly for something less massive anyway.


    [​IMG]


    Pretty pleased with the look. Just gotta turn up a little cuff to attach the midpipe to the headpipe. They are identical size, so I just need to make a little something to slip the two together. It looks ridiculously long in these pics, but in person the length looks right. If I slide the muffler any further forward I think it will start interfering with my throwovers. It's packed pretty slim as it is. Getting there...

    [​IMG]



    [​IMG]

    [​IMG]
    #99
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