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Old 03-24-2012, 04:57 PM   #106
okeydokey
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Location: Derbyshire (UK)
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Quote:
Originally Posted by Ghost_Mutant View Post
I don't see the reed valve holes in your intake ports. So your head may be the first time I've seen an RFVC XR500R without the reed valve. That's good. Honda's manual says they made them that way, but both of my 84 heads have the reed valve and ports
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??
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Old 03-24-2012, 09:42 PM   #107
Ghost_Mutant
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Quote:
Originally Posted by okeydokey View Post
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??

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.
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Old 04-23-2012, 07:15 AM   #108
Ivanych OP
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The project continues!!!!

Hi guys!
Spring has come!
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.

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


XR650l - rear swingarm, rear brake mechanism (cylinders, reservoir, pedal)


XR600r - rear wheel

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


Ivanych screwed with this post 04-23-2012 at 09:38 AM
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Old 04-23-2012, 07:34 AM   #109
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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.


Do fitting!!!


All connected!!!!!!!
I am satisfied with the!!!!!!!
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Old 04-23-2012, 08:04 AM   #110
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more photos

Fitting the radiator, the lock will be removed.

swing arm XR650l and frame XR500r

arm, rod assy
and axles


the length of the different


The combination of parts xr650l and xr500 requires manual mechanical completion.






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Old 04-23-2012, 08:32 AM   #111
brucifer
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Looking good, Ivan! Your friend looks real happy.
__________________
2007 Suzuki DR650SE-2000 Buell M2 Cyclone-Plated 1995 XR600R-1993 Kawasaki KX500-1984 Honda XL600R/XR650L Hybrid-1984 Yamaha TT600L-1980 Honda CB750F

XL600R Build http://advrider.com/forums/showthrea...4+xl600r+build
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Old 04-23-2012, 09:49 AM   #112
Ivanych OP
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Quote:
Originally Posted by brucifer View Post
Looking good, Ivan! Your friend looks real happy.
A long working day and unexpected photography.

MR. BRUCIFER,
I'm walking in your footsteps!
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Old 04-23-2012, 08:24 PM   #113
Ghost_Mutant
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Since I'm planning on updating my 84 with the same modifications, you can tell me how it gets done!

Looking forward to seeing the final result.
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Old 04-24-2012, 12:45 AM   #114
Ivanych OP
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Quote:
Originally Posted by Ghost_Mutant View Post
Since I'm planning on updating my 84 with the same modifications, you can tell me how it gets done!

Looking forward to seeing the final result.
The expected Result should be something like this :
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Old 05-07-2012, 11:48 AM   #115
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Worked as a welder today.
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)


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Old 05-08-2012, 01:11 AM   #116
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opened motoseason!!!

In St. Petersburg, opened motoseason!!!
Here's a quick overview of how it was:
http://www.youtube.com/watch?v=ncq7vwN8pRs
http://www.youtube.com/watch?v=I_pTd...eature=related
http://www.youtube.com/watch?feature...&v=Aoo_SNjbNPQ
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Old 05-08-2012, 02:43 PM   #117
mikejohn
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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
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Old 06-29-2012, 06:43 AM   #118
Ivanych OP
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new transmission!!!!!!!!!!!

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.



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



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

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

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


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Old 06-29-2012, 09:07 PM   #119
Ghost_Mutant
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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
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Old 06-29-2012, 09:22 PM   #120
RED1
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You should have gotten a 600R or 650L frame, engine would fit! But not as much fun modifying
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