Very useful, thanks. I’ve just acquired a completely stripped XT500 to rebuild so this will be very helpful. It’s currently in multiple boxes of rusty jigsaw bits.
Great sharing! You are a master! I have SR400, but your sharing is a good example. I plan to change the SR500 crankshaft, and your sharing is very helpful!
I fulfilled my promise. I got an SR500 engine today. I will use that engine for training. The additional benefit is that I got the SR500 crankshaft, I will tell you when I succeed.
Back in 81 I was a mechanic in a Yamaha dealers in Glasgow . As part of our training we had to go down to Mitsui HQ and rebuild an engine . I got an XT 500 👌🏻 Hated all those Philips head screws though !
Late to the show. But i noticed that you did not replace the cam oiler line from the pipe to a larger flow hose. I had a 77 tt500 and that was one of the first things i did.
I had one too, I got about 1200 miles and I was hit by by a 14 year old girl who stole her mother's car.. I lost my leg just below my knee..Man I miss this bike.
Got a big-end knock on my '77 so got to strip mine down. I have been told the screws have a J.I.S. head so have bought the screwdriver. Hope they are now. Great video, thanks
Looking into restoring my dad’s old 79. Will you put us in a direction in finding all the parts? And how long this project took to complete? I really appreciate it
Check a Web sites called KEDO Yamaha parts. They specialise in XT500s. I believe that its a franchise and operates form a few country's around the world. I reckon it was about 8 month. Getting the forks rechromed was expensive and took about 2 month. There are some replacement stantions Available for the later modles so hunt around. They are a great classic bike now. I always get lots of attention at the bike shows with it.
@@mostlymotorcycles. Ok great. Thanks for the feedback and for sharing your progress! I pulled his bike apart nearly 15 years ago with the same intention. I was a kid with a lot of ambition and little know-how. The parts landed in sealed barrels behind the shop and I never forgave myself. It’s time.
Man you are fast. Knock off 10 motors/day. 😝 Thank you for video. Picked up 76 XT500 with dick mann cross country frame, fox shocks. Looking forward to this project.
Awesome video, I missed the part where you installed the shift shaft, do the crankcase halves need to be split for that? My splines are worn out and besides a tack weld I can't think of another repair. Blue skies
Just standard engine lube. I’m not sold on assembly lube. If you think about it a bike can sit around for weeks and not get run. In that time most of the oil will have run off the components anyway. So, the engine will be short of lube for a few seconds after a start. You can always pull out the spark plug and give it a few kicks to circulate the oil before starting. I’ve done the same with a few car engines rebuilds, pull the plugs and crank the motor under low load until the oil pressure light goes out. Car engines run plain bearings of course, so are more sensitive to lack of lubrication then the ball races in the XT.
@@mostlymotorcycles. Pull the spark plug so you can kick it over a few times??? Why not just squeeze the compression release and kick it over? My 81 would sit all winter under a deck, exposed to wind and blowing snow. Every spring, I'd have it running in 3 kicks. Damn thing just would not die. Awesome bike! Finally sold it last year, with only 10,500 miles on it.
Way cool! Rebuilding my 76 TT500 now, just top end though. Valve seals, rings because I am burning oil. Assuming through valve seals because it is alot. Who did the paint? Powder coat? If I am doing just top end is there a way to clean the piston or should I just replace it? Thank you
Burning oil is probably piston rings. Easy way to tell is if it blows more smoke under heavy acceleration then oil is blowing past the piston rings. If more smoke is observed when you close the throttle from high speed then oil is getting sucked past the valve stem seals. If the engine is out of the bike I would pull the barrel of and check the piston and rings. Earlier models had an issue with piston wear If ridden hard. Painted the engine myself. Used enamel paint as it's quite heat resistant, but do your own coating research on the paint. There's a few more engine paint vids in the playlist.
Nice video! Watched intently as I may pick up a TT500 and wanted to see what the insides look like first! The clutch spring bolts- are they not sensitive to torque, as long as they are 'close enough'? I know with my DR350, people are very anal about getting ~4 ft/lbs on each bolt, else you get clutch problems.
The bolt heads bottom on the spring guides so bolt tension does not effect clutch operation. I just use my inbuilt torque wrench and experience on the smaller nuts and bolts. But you should follow the manual if not comfortable with doing it by feel.
@@mostlymotorcycles. Good to know! The DR350 bolts don't bottom out so it makes sense why it's a tad more finicky. And the inbuilt torque wrench is the best one to have, after some experiential calibration of course..
Can be done with tank off and tappet covers removed. Hardest part is getting the valve spring collets off without pushing the valves into the cylinder. Having the piston at top dead centre is essential of course to hold the valves up. I’ve also seen a modified spark plug with an air compressor hose connector attachment to use compressed air to pressurise the cylinder and hold the valves closed. Once the springs are off its easy to remover / replace the guide seals.
Are yes. The editing room is a tough master. Fine line between a vid being to long and editing out the less important bits. From my perspective anyway.
@@mostlymotorcycles. Understood and I do appreciate the effort; unfortunately, I am about to replace the cam chain on my TT500 so was particularly interested in that part of the build. I could find no other clear photos or documentation on what's involved so I think including that bit would fill a needed gap. Perhaps I'll do a video myself when I replace my chain.
@@mostlymotorcycles. Can you tell me if the lower sprocket for the timing chain slips on and off or does it need a puller to get it off and needs to be a pressed on ?
Sorry, und den Gehäuse Ölring, zudem die Hülse in der hinteren Motorhalterung. Für die Kurbelwelle gibt's Einziehwerkzeug. Kurbelwelle u. Getriebe setzt man ganz leicht und richtig in die linke Seite ein. 1.Getrieberäder 2. Schaltklaue nach rechts u.links versetzt einsetzen. 3.Schaltwelle einstecken. 4 Schalklauen an Welle in Position bringen.
Very useful, thanks. I’ve just acquired a completely stripped XT500 to rebuild so this will be very helpful. It’s currently in multiple boxes of rusty jigsaw bits.
Nice, long road ahead to the finished bike. But the rewards are well worth it.
Great sharing! You are a master! I have SR400, but your sharing is a good example. I plan to change the SR500 crankshaft, and your sharing is very helpful!
I fulfilled my promise. I got an SR500 engine today. I will use that engine for training. The additional benefit is that I got the SR500 crankshaft, I will tell you when I succeed.
Thank you a lot for taking the time to make the video, I did the same on my 5f0 and your video helped me.
Nice work. Soon to try the same. As with any engine: the casting, machining and assembly; are evidence that the "ape", has come far!
Back in 81 I was a mechanic in a Yamaha dealers in Glasgow . As part of our training we had to go down to Mitsui HQ and rebuild an engine . I got an XT 500 👌🏻 Hated all those Philips head screws though !
Magnífico trabajo, amigo. Saludos desde Colombia!
Late to the show. But i noticed that you did not replace the cam oiler line from the pipe to a larger flow hose. I had a 77 tt500 and that was one of the first things i did.
I had one too, I got about 1200 miles and I was hit by by a 14 year old girl who stole her mother's car..
I lost my leg just below my knee..Man I miss this bike.
If it can move it's your enemy
I'l be using this video to help me rebuild my 1978 SR500 engine.
Beautiful. Very enjoyable to watch. Thanks.
Just the video I wanted to watch to kick-start my xt 500 project thanks heaps !
Subscribed too mate !!
Надо было на горячую подшипники на коленвал насаживать,а затем блок нагреть и собрать двигатель.обошлось бы без всякого молотка.
Great work. Thanks for sharing
Not long finished one of these, great bike, nice job man
Awesome thanks. How yours running seet as, I'd guess.
Got a big-end knock on my '77 so got to strip mine down. I have been told the screws have a J.I.S. head so have bought the screwdriver. Hope they are now. Great video, thanks
Great video. Might be PMing you in the future. Beginning the tear down process of my XT as well.
Danke für dein tolles und übersichtliches Video 👍😎
2 complaints shouldve pressed the crank heated the bearing and also soak the clutch plates in oil before assembly
Que espectaculo....
very nice!!!
Nice repair on the clutch
Would be better not to break it in the first place, lol.
@@mostlymotorcycles.
Not wrong, but good repair
Very impressive!!!!
Precise work. Greetings :).
Beautiful !......not you Sir your engine rebuild, love that xt 500
Good job fella.would have liked to see just before the 20 min mark where the chain miraculously appears fitted down low.
Fantastic job, I have the same bike but i dont have the skill to do that. Impressive!
Man sure would be nice to know you as a neigbor ( man it not going to fix it self.) :- )
I love this...You old Bloke.
I LOVE THUMPERS
What an effort! An interesting watch, for sure.
I have a 1976 Yamaha 400 XT Heaven problems with it starting I believe it's a carburetor issue
I hear ya. Can be a process of elimination on these old bikes.
Looking into restoring my dad’s old 79. Will you put us in a direction in finding all the parts? And how long this project took to complete? I really appreciate it
Check a Web sites called KEDO Yamaha parts. They specialise in XT500s.
I believe that its a franchise and operates form a few country's around the world.
I reckon it was about 8 month.
Getting the forks rechromed was expensive and took about 2 month.
There are some replacement stantions
Available for the later modles so hunt around.
They are a great classic bike now. I always get lots of attention at the bike shows with it.
@@mostlymotorcycles. Ok great. Thanks for the feedback and for sharing your progress! I pulled his bike apart nearly 15 years ago with the same intention. I was a kid with a lot of ambition and little know-how. The parts landed in sealed barrels behind the shop and I never forgave myself. It’s time.
The missing part is - fire that damn hammer on !!! Let us hear the music 🙂🙂🙂
Who needs a crankcase puller when you got a hammer. Lol
I would've got another clutch basket.
Man you are fast. Knock off 10 motors/day. 😝 Thank you for video. Picked up 76 XT500 with dick mann cross country frame, fox shocks. Looking forward to this project.
Really great video but just one thing. Reconsider the text, green with shadow is not doing this great work justice- almost unreadable!
Another good video.
I wish you mentioned how many hours it took you to assemble the engine.
That was a days work.
Awesome video, I missed the part where you installed the shift shaft, do the crankcase halves need to be split for that? My splines are worn out and besides a tack weld I can't think of another repair. Blue skies
It will come out with the clutch cover removed. I can't remember if the clutch basket has to come off as well.
Why are you putting gasket paste on top of a layer of oil between the two cases?
Makes it much easier to clean off if you must disassemble it again. Oil wont effect the seal.
DonYourHelmet aah i see, im restoring an xt engine as well. I will make a video too ;)
what did you have in that oil can - just 10W30 or some kind of special assembly lube?
Just standard engine lube.
I’m not sold on assembly lube. If you think about it a bike can sit around for weeks and not get run.
In that time most of the oil will have run off the components anyway.
So, the engine will be short of lube for a few seconds after a start.
You can always pull out the spark plug and give it a few kicks to circulate the oil before starting.
I’ve done the same with a few car engines rebuilds, pull the plugs and crank the motor under low load until the oil pressure light goes out. Car engines run plain bearings of course, so are more sensitive to lack of lubrication then the ball races in the XT.
@@mostlymotorcycles. Pull the spark plug so you can kick it over a few times??? Why not just squeeze the compression release and kick it over? My 81 would sit all winter under a deck, exposed to wind and blowing snow. Every spring, I'd have it running in 3 kicks. Damn thing just would not die. Awesome bike! Finally sold it last year, with only 10,500 miles on it.
What sealant diid you use on the rocker cover?
Sorry i don't remember. Probably a high temp black silicone.
Way cool! Rebuilding my 76 TT500 now, just top end though. Valve seals, rings because I am burning oil. Assuming through valve seals because it is alot. Who did the paint? Powder coat? If I am doing just top end is there a way to clean the piston or should I just replace it? Thank you
Burning oil is probably piston rings. Easy way to tell is if it blows more smoke under heavy acceleration then oil is blowing past the piston rings.
If more smoke is observed when you close the throttle from high speed then oil is getting sucked past the valve stem seals.
If the engine is out of the bike I would pull the barrel of and check the piston and rings.
Earlier models had an issue with piston wear If ridden hard.
Painted the engine myself.
Used enamel paint as it's quite heat resistant, but do your own coating research on the paint.
There's a few more engine paint vids in the playlist.
Nice video! Watched intently as I may pick up a TT500 and wanted to see what the insides look like first! The clutch spring bolts- are they not sensitive to torque, as long as they are 'close enough'? I know with my DR350, people are very anal about getting ~4 ft/lbs on each bolt, else you get clutch problems.
The bolt heads bottom on the spring guides so bolt tension does not effect clutch operation. I just use my inbuilt torque wrench and experience on the smaller nuts and bolts. But you should follow the manual if not comfortable with doing it by feel.
@@mostlymotorcycles. Good to know! The DR350 bolts don't bottom out so it makes sense why it's a tad more finicky. And the inbuilt torque wrench is the best one to have, after some experiential calibration of course..
Did the lower oil feed pipe not get fitted?
Couldn't see it anywhere in the video.
Like hens teeth on the internet.
It sure did or it wouldn't run for to long.
It's probably in the final assembly vid.
What did you use for engine paint?
Can you rebuild one for me?
Where did you get this engine parts from
kedopartsaustralia.com "Kedo" is a franchise so do a search in your country.
How hard is changing your valve seals?
Can be done with tank off and tappet covers removed. Hardest part is getting the valve spring collets off without pushing the valves into the cylinder. Having the piston at top dead centre is essential of course to hold the valves up.
I’ve also seen a modified spark plug with an air compressor hose connector attachment to use compressed air to pressurise the cylinder and hold the valves closed.
Once the springs are off its easy to remover / replace the guide seals.
@@mostlymotorcycles.
Another way is to feed cord or rope into the sparkplug hole and roll the crank to compress the rope up against the valves
You skip showing putting the cam chain on the lower sprocket
Are yes. The editing room is a tough master. Fine line between a vid being to long and editing out the less important bits. From my perspective anyway.
@@mostlymotorcycles. Understood and I do appreciate the effort; unfortunately, I am about to replace the cam chain on my TT500 so was particularly interested in that part of the build. I could find no other clear photos or documentation on what's involved so I think including that bit would fill a needed gap. Perhaps I'll do a video myself when I replace my chain.
@@marksutton8820
I don't know if this will help but have a look at it anyway
th-cam.com/video/v-ewT7GsiNU/w-d-xo.html
@@mostlymotorcycles.
Can you tell me if the lower sprocket for the timing chain slips on and off or does it need a puller to get it off and needs to be a pressed on ?
@@marksutton8820
... and do you have to break and rivet the timing change or can it go on without needing to be broken ?
If you understand what I mean
How much is your engine machine?
Sorry don't understand the question.
Engine displacement is 500cc
cool video but the green writing wasnt great ,, too small and had to strain to read it ... I'm mid 20s btw..... :P
Are yes the green titles were a rookie error.
💪🏻💪🏻💪🏻👌🏻👌🏻🇨🇴🇨🇴🇨🇴🇨🇴
Alter, du hast 2 o-ringe vergessen!
Zylinderfuß, und ölfilterdeckel!
Mfg
Sorry, und den Gehäuse Ölring, zudem die Hülse in der hinteren Motorhalterung.
Für die Kurbelwelle gibt's Einziehwerkzeug.
Kurbelwelle u. Getriebe setzt man ganz leicht und richtig in die linke Seite ein.
1.Getrieberäder 2. Schaltklaue nach rechts u.links versetzt einsetzen. 3.Schaltwelle einstecken. 4 Schalklauen an Welle in Position bringen.