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Old 05-16-2011, 08:31 PM   #61
jub jub
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That clutch basket has seen better days.
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Old 05-16-2011, 09:18 PM   #62
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That clutch does look worn. Remember that the XR500 has a unique clutch basket with different buffer springs from the XL600/XR600. I picked up a cheap XR600 clutch thinking it would be a good spare, but then I noticed the bigger springs. One more thing that is different about the 500s.

I wonder if the clutch basket rivets could be removed and the springs swapped? That way a new XR600 basket could be used in the XR500 with the stock springs. But I decided that my clutch baskets had some life left in them, so I put the engines back together with the original baskets:
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Old 05-17-2011, 11:23 AM   #63
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Quote:
Originally Posted by Ghost_Mutant View Post
That clutch does look worn. Remember that the XR500 has a unique clutch basket with different buffer springs from the XL600/XR600. I picked up a cheap XR600 clutch thinking it would be a good spare, but then I noticed the bigger springs. One more thing that is different about the 500s.

I wonder if the clutch basket rivets could be removed and the springs swapped? That way a new XR600 basket could be used in the XR500 with the stock springs. But I decided that my clutch baskets had some life left in them, so I put the engines back together with the original baskets:
THIS IS HUGE WEALTH!!
THESE ENGINES HAVE SPARE FOR YOUR TWO BIKE??
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Old 05-18-2011, 07:17 AM   #64
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The two engines in my last photo are now in the bikes. I took that photo during my rebuilds. I was trying to find a good shot of my clutch baskets, and this photo is what I found in my collection.

I do have spare parts from a third XR500, but not enough good parts to build a complete engine.

The engine on the left in the photo is from my main 84 XR5. The engine on the right was rebuilt from parts I found in boxes from the two additional damaged machines I bought for cheap. This bottom end is from an 84 that had the top end damage. The cylinder, piston, and head are from the 83 parts machine that had the transmission/clutch damage.

Both engines have new valves, rings, timing chains, seals, etc. The heads had valve seat work. The 84 on the left was bored to 1st oversize. The cylinder from the 83 on the right was already on its 2nd oversize and it was within specs, so just its piston rings were replaced.

The oil pumps are used units from a newer XR600 that have the internal seals. The oil pump drive gears were changed to the newer parts that spin a little faster providing more oil flow.

I used the 84 carb boots to get the cross port for both engines. Then I also plugged up the reed valve ports as shown in the previous photo.

I completed these rebuilds late last year, but I'm still looking for some time to get the dirt only 83 machine into the mountains for a long ride.

My 84 has an early Baja Designs dual sport kit. I may decide to upgrade the stator and change out some of these older parts.

Plans now include:
-building up the third bottom end with new transmission that has wide gearing. I do need to measure the output shafts to be sure I can do this.
-oil coolers
-float gauge/sight glass for frame oil tank
-flow indicator for head oil pipe

But since the bikes are working and I've got other priorities in life, I've scaled back on how much time I spend working on these extras.
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Old 05-22-2011, 08:13 PM   #65
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transmission comparison

Got the spare transmissions out of the attic to do a quick comparison.

Top is 83 XR500, middle is 88 NX650 (note output shaft splines), bottom is XR650L


With gears removed from output shafts:


The shafts are not interchangeable. You can swap the entire transmission, but not all of the gears can be swapped onto the XR5 shaft.

In order to change my XR5 gearing to the newer/wider gear ratios, I now need to get a XR600 output shaft. The NX output shaft is missing the kick start gear section on the left end in the photo. The XRL has some metal there, but it's not machined.

The newer transmissions are more robust. These new gears have more engagement points which you can see in the above photo. The XR5 has 3 engagement points, but the other bikes have 5.

Here is a closeup showing why I think my 83 XR5 became a cheap parts bike with the case already split apart:

The XR5 shaft is on the left in this photo. You can see the bevel worn into the engagement pins. I'd guess that the bike popped out of gear on the previous owner.
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Old 05-24-2011, 02:31 AM   #66
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Hi everyone!
This weekend went well!
I ended up (still works fine) work to restore my other bike !!!!!
This JAWA 350 (1990 year), bike is made in the Czech Republic (the Republic of Czechoslovakia).
He was out of work 18.
JAWA legendary motorcycle brand in Russia. About JAVA dreamed all adolescents 70-80 years.
I made the change:
Rubber parts
Gaskets
Candles
Oil
The battery pack
Clutch Cable and carburetor
New hoses and filter
Made washed viscera
Bulkhead carburetor.
Details of the ignition and electrics.

I filled the petrol, shook the mixture twice hit the Kick and she earned !!!!!
I like the old classic motorcycles.
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Old 05-24-2011, 02:35 AM   #67
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Collected by!!!
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Old 05-24-2011, 06:39 AM   #68
jub jub
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Nice looking Jawa you got there Ivan!

Got to love the old two strokes!
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Old 05-24-2011, 10:23 AM   #69
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Must return to the main topic.
Here's what's been done on XR500r
Manufactured a device for removing the clutch, clutch shot, Kick, oil pump.
Kick starter spring is broken.
On the clutch near the springs are visible traces of contact with other items.
Had a broken strap ratchet Kick.
Some clutch spring free to move (they have a backlash).
Is that correct??
Now I need a new spring and the bracket for the Kick.
A list of required items is increasing. My wallet is thin.
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Old 05-24-2011, 10:31 AM   #70
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Device for removing the clutch
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Old 05-24-2011, 10:34 AM   #71
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the clutch
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Old 05-24-2011, 10:35 AM   #72
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Kick starter spring
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Old 05-24-2011, 10:37 AM   #73
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I could not remove the generator rotor. I had a bolt M22 * 1.5, brass, and twists it into the rotor (rotor will become hot heat dry). But the bolt thread has deteriorated, and I failed.
Suggest a way to remove the rotor. Who knows?
I need to split the motor and see the interior to assess.
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Old 05-24-2011, 10:39 AM   #74
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Ghost_Mutant thank you for your research output shafts. It is very important.

I did a little research vendors Honda parts from the U.S. to Russia.
I think I will have the chance to buy many items directly to the U.S..

My English is very bad and I use to help the Google translator.
You guys can understand me?
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Old 05-24-2011, 07:33 PM   #75
Ghost_Mutant
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Quote:
Originally Posted by Ivanych View Post
Ghost_Mutant thank you for your research output shafts. It is very important.

I did a little research vendors Honda parts from the U.S. to Russia.
I think I will have the chance to buy many items directly to the U.S..

My English is very bad and I use to help the Google translator.
You guys can understand me?
I have guessed that you were using a translator.

Communication is working alright. Photos help the most.

Was the clutch basket wearing on the broken spring? I haven't seen that kind of wear on any of the 4 baskets I have (3 XR500s, 1 XR600).

The buffer springs shown in your basket photo are the ones I mentioned earlier. I believe they are unique to the XR500.


EDITED
Do you have a Honda manual?

You could probably use the XL600 manual if you don't have one. Just remember that there are some differences.


Get it here:

http://www.hondaxl.it/manuali.htm


You have your choice of Italian or English


Never mind, I read your first posting again and I see you already have the proper Honda manual.



I have one of these to remove the flywheel/rotor:

http://www.motionpro.com/motorcycle/partno/08-0074/


Many years ago, I had one of these:

Ghost_Mutant screwed with this post 05-24-2011 at 07:40 PM
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