1985 500XS

[Shayne Hall]

Hi Guys

I recently aquired a 1985 500XS . Its been stripped down and i intend rebuilding. Attached a few photo's. I have a more detailed thread in the Cafe Diner under unknown 500. I will hopefully be collecting the frame and swingarm etc tomorrow for more pics.



The bike came with the kickstarter out but i seem to have managed getting that together again. There is an additional Cog and small spring which i suspect has been left out of the other side of the clutch casing. I will strip that section tomorrow to confirm.

The bike came with a spare center casing, clutch big cog and complete bare with no scores etc.




Where can i aquire additional parts like a complete kickstarter? I have downloaded a workshop parts manual so i have the part numbers.

Im in South Africa so on the other side of nowhere for shipping.

 

[husky jim]

The motor # 0992 is a 1985 but you have the extra bolt on the primary cover above the kickstarter, and the extra bolt on the airbox cover. Those were both updates on the 1986.

 

[evcross0]

Phil at Husqvarna-parts.com is probably your best bet for parts. Ebay is also a good source. your bike is probably the 85/86 500 XC. You can go to Phil's website and look under bike ID to tell exactly what you have.

 

[87husky500xc]

husqvarna-parts.com Site is great and lots of parts as well as good customer service

 

[Shayne Hall]

Awesome thanks for the promt and informative responces guys.

Picked up the rest of the bike today. Sooo excited to get it stripped down completely now and get the ball rolling.

I saw in a post the other day sandblasting and powder coating is most probably the best route to go rather than just painting. Bike is missing the gear selector ans sidestand.

 

[86 400 XC]

looks like a good start to a fine bike.

I like the rotor home made perhaps?

 

[evcross0]

Actually I think that's an original early disc. They didn't work well at all. I"ve been working on adapting a modern KTM complete front brake system with a custom modern rotor.... Not done yet.

 

[Shayne Hall]

yes i gathered that may be the case. No ventilation. I have a friend who works at Honda for the lats 30 years and used to race agains Alfie Cox, they are still good friends, so he may be able to assist with any "modern" upgrades. I prefer to stay as original as possible but breaking is a safety aspect where this can be overlooked.

I noticed a bolt on the one site of the cylender head. It is also on the spare head that i recieved. Does anyone think this may have been for some sort of decompression unit? A trype of pre drilled hole which is on "standby". It can be seen in the pic, close to the location of the exhaust port. I remember my 1989 NS125R also having this. Never really figured out the function? I cant see any holes in the barrel or the water coolant cooling system chamber.

 

[evcross0]

if your talking about the 10mm hex head on the side of the cylinder, that's the water jacket drain plug...

 

[Shayne Hall]

ok thanks.

does anyone know if there is a nut and bolt kit for the 500xs. Many of mine are very rusted so im going to replace but its much easier to buy a complete bolt etc kit.

Otherwise it will take a very long time to sit at a company finding each one. Im also sure a lot of these are bush mechanic replacements.

 

[Shayne Hall]

Is there also a wiring harness which is purchasable. I ve looked on some sites and my post above and this one do not have these options.

 

[suprize]

download the parts manual and write down the bolts you want and send that to the bolt shop...let them fill out the order. if you powdercoat, remove the steering races and degrease well as the high temps brings any grease or oil dribbling out! also screw oldbolts into any threads as the powder will fill the threads and they will need retapping. send all your good bolts for plating and get all your alloy bits water blasted

 

[husqyhamm]

Shayne
Im located in Gauteng and have parts and know-how to get and keep them running.
PM me

 

[suprize]

Problem will be solved, next pics should be on the way to rebuilt! enjoy

 

[Shayne Hall]

Awesome thats great husqyhamm. How can i get hold of you for more info?

Ive sent the frame in for the mean time for powder coating, some of the threads were tight so i will retap with M6 and M8 thread taps.

Stripped the endine down and see the waterpump casing has corroded, of which the previous owner rebuilt with and metal adhesive of some sort. I would prefer to obtain a new casing cover.

Wheels went in as i was unable to remove the tyres. Fortunately a very good friend of mine works at Honda Sandton so his service dept is gonna take them off as well as strip down the forks for me. Some things better left to the pro's.

Need to start aquiring the bolts etc and new bearings, seals etc.

Its happening slowly.

 

[husqyhamm]

Shane, I sent you my contact via PM.

 

[Shayne Hall]

cool thanks.

My friend will be here soon who stays in Grand Rapids Michigan. He is bringing in all the parts i bought. Gaskets, tank cap, brembo caliper and fluid chamber rebuild kits etc etc. Small things which will be hard to here and easier when saving shipping costs and import duties etc.

Cant wait to get the gaskets to reassemble the engine. Ordered all the bolts for the bike through the company i work for as if im r"eselling" to a customer so i qualify for 35% discount. Score.

 

[Shayne Hall]

Started stripping my rims.

Both need to be replaced, as well as spokes. Front:1.60 x 21" - 36 spokes : Rear 2.50 x 18" - 36 spokes.

Found the Excel rims dimpled on Buchanan Spoke & Rim but not sure on the nipple, spoke length, ga and angle that they request. Does anyone know what exactly what i require as i dont want to bring in the wrong items.

 

[2premo]

a good upgrade that works for the brakes is 87-88, you need a hub or complete wheel the caliper and forks, the triple clamps are the same, can't remember off hand if the axle works, but really helps the braking, bigger pads and stops way better
also it's oem fit and finish quality