Between January and February I tore apart the engine on my 1979 Honda XL500S to fix some oil leaks in the head. Things would have gone faster but I needed to buy some extra seals that I hadn’t expected on needing and my schedule has been very tight with graduation fast approaching. This is the engine partially torn apart on my workbench in my apartment.
I devised a tool to replace the valve seals.
A bronze bushing cut into pieces and held in place by a big C-clamp worked pretty well. Obviously a $150 tool would have been easier but for $15 this was good enough to do four valves.
After I finished rebuilding the engine, I brought the frame of the motorcycle inside my apartment. The weather has been rotten the last few months and I didn’t want to spend hours out in the rain and cold trying to force the engine back into place.
I got the engine back in with the help of a few of my boys. After re-tightening the spark plug, the bike fired right up and has been running great. In the future I might want to rebuild the carb and replace the choke cable but otherwise this thing is a good strong runner. It is a real hoot to ride, too.
i know how big of a pain it can be getting that motor back up into that frame lol. especially solo.
It certainly isn’t fun alone! Someday I’ll have a proper engine hoist…
How did you remove the motor?? I’ve heard its a terrible job!
It wasn’t too bad. I had a couple guys help me lower it out of the frame when I unbolted it. Could be done by one person with an engine hoist or a small come along to suspend the engine. I also used a rubber mallet to help dislodge some stubborn bolts.
Cheers!
Douglas
Hi I am from Deadwood sd not really that far from you ,I have a 79 xl500 in my basement where it has been for about 15 years I really need a gas tank for it to be complete my ques I have that and a 1977 500 Honda xt called an endure that year the Honda has 2300 miles and the Yamaha has 1200 I can only afford to do one of them but I would like to give it some spunk but still be a nice to town and back bike 3 mile round trip LOL which bike would you pick to build? Thanks Scott
Hi Scott!
I would see which bike turns over and seems to have the least amount of things that need to be repaired or replaced. Both of those bikes should be pretty simple to work with. If you need a new gas tank for the Honda, there are desert tanks available that are made out of plastic and have extra fuel capacity. Or $50 on EBay will get you a used tank in good condition.
Cheers!
Douglas
I have a 81 XL500R and I need some help. Sorry to butt into your comments but I can’t find a place to post MY problems. Can some one please direct me?
Howdy Joshua!
https://thumpertalk.com/ can probably hook you up.
Cheers!
Douglas
To remove the engine from the frame the trick is one hand on the kick starter and the other hand you insert two or three fingers in the exhaust port and shake it while you are lifting up
Yo where can I buy countershaft oil seal for my 79 xr 500? I’ve looked all over with no luck
Hi Matteo,
I’m not sure. It’s been several years since I rebuilt this engine. I think I bought my kit from Amazon before.
I’m sorry to say but ebays the only way. Goodluck