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Old 03-26-2009, 08:20 PM   #1
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82' Honda XL185s rebuild

So for quite a while I have avoided the whole motorcycle thing. I always tend to have a few too many hobbies at one time, and i always saw motorcycles as being the straw that would break the camel's back. I graduated college in December, perfect timing to start looking for jobs that don't exist. With no income since June, I haven't been able to feed money into my subaru wrx and golf GTI rally car. Since every time I think about working on those cars the numbers are three, if not four digits, it was time to find a cheap project to keep my hands busy. ahhhh I remember there was a bike tucked away in a barn at my girlfriends parent's hobby farm, it turns out to be a 1982 Honda XL185s, a few questions later I was told that if I got it running he'd sign the title over to me . Here it is in a deep slumber:

pulled it out to blow some of the dust off and get a better assessment of the situtation:


Looks to be mostly there. One of the GF's brothers pulled the lights off a while back to make it look more like a dirt bike, tires are rotted, chain looks bad, seat cover needs to be replaced, fork and bars are a little twisted from being droped... give it a kick over and it's seems to be decent inside seems like a good project. In the end I can have a bike that is good enough to cruise around on some county roads for adventures, but more importantly will be a decent first bike as well as being basically the best moped ever for around the cities

Last saturday my friend Brian (captianpegs) and I decided to get it started. Poured the old gas out of the tank, cleaned the carb out and poked a blocked jet out with a needle. with a little starter fluid it fired up and we were able to give it a spin:

The engine seems strong, but both of us were unable to get 5 gears. 0 down and 4 up... looks like all those years as chasing cows as a farm bike took it's toll on 1st gear. We figured it was best to quit running the bike and drop the oil to see what the scoop is:


and so begins the project
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G2mk3 screwed with this post 03-26-2009 at 08:51 PM
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Old 03-26-2009, 08:26 PM   #2
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Tonight I finally mustered up the energy to go pull the engine... WOW is this bike stuff SOOOOO much easier than working on cars. Unbolt the carb, throttle cable, clutch cable, wiring for the ignition, chain, exhaust, 7 bolts for the engine and it practically fell out:



We found last weekend that other people claimed the bike to be home for a while:

My cat chairman meow confirmed our hypothisis "where are those mouses! LET ME AT EM'":
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Old 03-26-2009, 08:32 PM   #3
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I've already got some gaskets for the carb and a new air filter from Honda, a Keyster carb kit (i've heard good and bad things, so we'll see how it compares to what comes out of the carb) and a factory service manual off of ebay

I think tomorrow we'll be opening the engine up to see how bad the gearset is and if the metal bits did any damage elsewhere. Any pointers on taking the engine apart would be much appreciated, I've heard of special tools for the clutch... any way to avoid buying that sort of thing? Also, do people ever mess around with the dog teeth on the gears? On the rally cars the conditions of the dogs always made a huge difference, but I'm not sure if they will have such an effect on the small bike transmission.
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Old 03-26-2009, 08:44 PM   #4
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What the??!!

What do you plan to do with this rocket? Is this a learning experience or do you plan on actually using this moped? Hell, I bet a CM400T could even smoke this thing!!


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Old 03-26-2009, 08:51 PM   #5
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easy now.... thems fight'n words!
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Old 03-26-2009, 10:11 PM   #6
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Check the needle on the Keyster kit and report back!
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Old 03-27-2009, 06:16 AM   #7
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Ha! Maybe the "captain" just doesn't posess the maturity to enjoy a decent little trail bike.. Hell, there's nothing wrong with a 400t either for that matter..

Build the little 185, have fun with it..
Besides, have you ever tried riding a street bike on trails?
Different bikes, different days, moods, terrains, they all have their strong suits and most can be enjoyed when ridden in their elements by a rider pointed at the proper objective.. Enjoying things for what they are and not being hung up on some power trip..
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Old 03-27-2009, 06:40 AM   #8
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Quote:
Originally Posted by DoubleBit
Ha! Maybe the "captain" just doesn't posess the maturity to enjoy a decent little trail bike.. Hell, there's nothing wrong with a 400t either for that matter..

Build the little 185, have fun with it..
Besides, have you ever tried riding a street bike on trails?
Different bikes, different days, moods, terrains, they all have their strong suits and most can be enjoyed when ridden in their elements by a rider pointed at the proper objective.. Enjoying things for what they are and not being hung up on some power trip..
Naaaw, if you re-read the firt post you'll see that captainpegs is a friend of the OP and is helping with the project. Just trash talk between buddies it seems...
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Old 03-27-2009, 07:16 AM   #9
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I want to see a pic of the full "Knockout" poster. . . haha looks awesome

Boxer on a Ferrari?
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Old 03-27-2009, 08:39 AM   #10
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My bad, just reacting to one of my pet peaves.. There is so much "profiling" in motorcycling, it can ruin the fun..
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Old 03-27-2009, 09:58 AM   #11
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brian: "I guess I don't make a very good noob"
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Old 03-27-2009, 10:18 AM   #12
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Simon, I quick pulled the needles to see if there are any differences, from what i can tell there are none (w/o using a micrometer). If there is a difference it's very small in the profile. I did notice that the original is stamped "60D" and they keyster is stamped "D62".

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Old 03-27-2009, 01:00 PM   #13
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Dang it!

My cover has been blown




Is there just one clip position on those needles?

(and that cat would make a NICE hat!)
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Old 03-27-2009, 01:37 PM   #14
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Cool. I'm trying to determine if the rumors about Keyster kit needle sizes being off from stock is true.

Sounds like there is some truth if stock is 60 and you got a 62.
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Old 03-27-2009, 02:07 PM   #15
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yes just one clip position on the needle. i think i'll keep the keyster needle as a spare, but unless i see huge differences i think i'm going to run the jets because i have a hard time trusting how clean i'd be able to get them.
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