I always wanted one when I was a kid. I finally got one! Still runs like a champ. I'm in the process of installing a new timing chain tensioner. Should have done it at rebuild but it's hard to get every detail!
Thanks! Yea, I did the best I could with stock. The plastic was beyond repair so I went with new but I did keep the old stuff. I built brackets for the new plastic side panels that didn't affect the frame in any way (machined, clamp on parts) so if I ever run across original panels I can put them back on easily.
Yes for sure - part dead ends a real danger when working on these bikes. I didn't know that going in but I lucked out and found what needed to finish the bike.
Awesome job! I did a complete remod on my '84 XR 500R also but decided to give it a modern look with new CRF plastics and graphics. It was a big decision whether to keep the stock look or modern one. Luckily for me l didn't have to do any engine repairs other than rebuilding the carbs. Well done!
Just before winter. This was my work release program. We drew jobs from a hat. Some of them were pretty bad but I got "rebuild vintage motorcycle in a nice heated shop at home". Lucky!
Parts are difficult to find. Engine parts especially. I don't really have any good sources I can recommend that aren't something you can find on the internet pretty easy. I got a lot of stuff from e-bay and plastics from DC Plastics. It's a tough one to get parts for but it can be done! If you get into the engine and rebuild it, I highly recommend replacing the timing chain tension mechanism as well as the oil sump ball valve mechanism. If you bike is worn, both of these might give you trouble in the future. Worn timing chain tensioner = noisy engine and worn ball valve = smoke at startup. Just a warning - loose conrod = trouble for you. You CAN'T find new conrods for these motors...
Hey, I'm currently rebuilding my 83 xr500r. Got any recommendations for the wiring? Everything has already been stripped just have a hard time finding the parts.
They are hard to find parts for. Mine was beat-up but the one thing that was in decent condition was the wiring harness. It came without a headlight but I was able to easily wire that back into the harness. I'm sorry but I don't have recommendations to make it easier. If it's missing the wiring harness, maybe you can find one complete?
Ha! Funny you ask. I was gonna leave that pic out because it's a little of a 1/2 aced repair and I wasn't too proud of it - but yes! So far so good. The metal was in really good condition outside of being dented so it's holding nicely and no delam or cracks or anything.
Back when I did this job there was a website a guy was running call "flashredbikes" if memory serves me correctly. He sold me a decal set. I can't tell you if he's still running the site or not. You'll have to google it and see if you can find it.
DC Plasics: SKU: HON-PK-1983XR500R $230 minus the tank. I kept the original plastics but they are not that great and beyond repairing into nice condition. The kit from DC is OK - looks good. You have to make your own mounting bolts for side panels and the front fender is kinda floppy but it's the only set you can find I think. Yellow decals not installed nor included. I think I got a new tank from CLarke if I remember correctly.
No - plastics including tank are all aftermarket. I did save all the OEM stuff in case I ever sell the bike or whatever. They were pretty faded. I started by trying to restore the tank but it just wasn’t going well so I just replaced all of it.
DC Plastics if memory serves me. A kit is the way to go. Very inferior to OEM for sure but not too bad. You'll have to punch holes in the fenders and get creative with side panel mounts to make it look nice. As for the tank, I simply don't recall. It might have been DC plastics but I kinda don't think it was. Side panels for these bikes are gold. If you actually found an OEM in good shape it would cost you a small forture - especially muffler/right side. I kept all my old plastic but it's not really that good of condition. I figured if I ever sold it maybe someone would want it.
@@paulhaines5755 I love it, I just got a 82 a few days ago for 700 and I’m following in your footsteps now. Do you know how easy it is to mix parts from different years on the xr series or transplanting parts from the crf?
Hmmm - that I am not sure of that. I mostly stuck to part numbers from the parts list specifically for this bike. I heard rumors of a spreadsheet that someone put together to help cross reference parts from year to year but I never used that resource so you might hunt around for that.
@@paulhaines5755 what do you believe was the most important part of your rebuild or the part you didn’t think would be as important to the whole process as you thought? Gasket material? OEM parts? Sanding/polishing tools? I’m just getting ready and need to know what not to forget until I need it
It was pretty outrageous. Keep in mind this bike was very thrashed. The engine needed almost everything so by the time I got done with that I was in too deep so I had to finish! It was between $3500 and $4000 I do believe.
If I did another bike I'd get one in better shape for sure and save some $. This project interested me because it was in such bad shape. I wanted something like this to really learn as much as I could and get a thorough picture of all that's involved from A to Z.
@@paulhaines5755 I have an 84 XR 500 that I am debating on restoration. I believe it would also be in the same $$$ range. Would you do it all over again?
@@SeanMolby If you have a tight connecting rod and good engine I probably would restore it. If you have any issues with the connecting rod then I wouldn't do it. Here's why: The top bore on the rod does not have bearings and is generally the first thing to go if the motor has ever been oil starved or is just plain used up. You cannot and I repeat cannot find new or aftermarket conrods for these bikes. I found one just by 100% luck and I think it was the last one left on earth! A loose conrod will cause issues with new rings seating and you'll have a noisy oil burner in no time. You can pay big bucks to have the conrod modified to a XR600 but it will cost you mucho. Parts are pretty hard to find. Really no new engine parts are to be found outside of pistons and rings and some stuff like that. OEM plastics in decent shape are non-existent. You'll have to go aftermarket with plastics and they are not as good and require a machinist level of home-made mounting brackets to make then look decent. Trust me - they don't just bolt on! If your plastics are in decent shape and you can refurbish them, it's a lot of elbow grease but worth it to save the OEM. With that, I'd say if you have a bike that's in pretty decent shape and has a pretty good motor, go for it! If it's beat to heck and has a oil burning engine that needs a lot of stuff, I'd go find something easier to work on such as a newer 600. If you like a big challenge then it might just be for you... (That's why I tackled it). Hope this helps! Ask for my e-mail if you have any more questions. I know this one inside and out.
Awesome! yea, as a youngster I always dreamed of having an XR500. I came across a few over the years that were kinda over priced and the wrong time for me. I bought this on at a yard sale on a spur of the moment decision and tackled it. It was a BIG project but I fulfilled a couple dreams. One was owning one and the other was rebuilding a poor condition bike to the best possible condition I could do.
Good job. I’ve had 6 of the XR’s and loved them all.
Thank you! It was a challenge to say the least but I'm very proud of how it turned out.
This bike is so beautiful. I had one 35 yrs ago 😊
Thank you!
"Jip i had one.. "They dont make the good stuff anymore.👀♥️
I always wanted one when I was a kid. I finally got one! Still runs like a champ. I'm in the process of installing a new timing chain tensioner. Should have done it at rebuild but it's hard to get every detail!
Its brand new..
just saw your video for the fist time this morning,awesome restore job.looks like it just came out of the crate👍🤙🤙.great job
Thank you!
Great rebuild of a cool bike! I like the decision to keep the stock look.
Thanks! Yea, I did the best I could with stock. The plastic was beyond repair so I went with new but I did keep the old stuff. I built brackets for the new plastic side panels that didn't affect the frame in any way (machined, clamp on parts) so if I ever run across original panels I can put them back on easily.
Looks awesome, I did a frame up on an 85 xr250r but it started out a lot better shape than you started with. Parts are very hard to find
Yes for sure - part dead ends a real danger when working on these bikes. I didn't know that going in but I lucked out and found what needed to finish the bike.
Very nice I'm working on an 83 Hopefully it will look as nice as yours
Good luck! Hope if goes well for you.
Awesome job! I did a complete remod on my '84 XR 500R also but decided to give it a modern look with new CRF plastics and graphics. It was a big decision whether to keep the stock look or modern one. Luckily for me l didn't have to do any engine repairs other than rebuilding the carbs. Well done!
Thank You!
That’s funny because I’m thinking about giving my ‘12 XR650l the retro look.
Most bad ass 500 dirt bike ever
Im in awe. Great job
Thanks! I appreciate that...
Hermoso trabajo....
I want to drive that bike. Its awesome.
Excellent build!
Just before winter. This was my work release program. We drew jobs from a hat. Some of them were pretty bad but I got "rebuild vintage motorcycle in a nice heated shop at home". Lucky!
Nice job looks great
Hey Mate the resto looks amazing can you put me onto some parts for the 84 XR 500 im restoring one myself!
Parts are difficult to find. Engine parts especially. I don't really have any good sources I can recommend that aren't something you can find on the internet pretty easy. I got a lot of stuff from e-bay and plastics from DC Plastics. It's a tough one to get parts for but it can be done! If you get into the engine and rebuild it, I highly recommend replacing the timing chain tension mechanism as well as the oil sump ball valve mechanism. If you bike is worn, both of these might give you trouble in the future. Worn timing chain tensioner = noisy engine and worn ball valve = smoke at startup. Just a warning - loose conrod = trouble for you. You CAN'T find new conrods for these motors...
Alan Millyard approves
Very cool build to say the least!
Hey, I'm currently rebuilding my 83 xr500r. Got any recommendations for the wiring? Everything has already been stripped just have a hard time finding the parts.
They are hard to find parts for. Mine was beat-up but the one thing that was in decent condition was the wiring harness. It came without a headlight but I was able to easily wire that back into the harness. I'm sorry but I don't have recommendations to make it easier. If it's missing the wiring harness, maybe you can find one complete?
get a custom harness
I had the xr 250r when I was growing up. Blew the top end in it and sold it very cheap. Kick my self in the ass now.
Ha! I feel your pain. I once sold a Dodge Dart for $400. Woulda been a cool car to build, now...
Awesome work!! I have an 83 xr500r, where did you find your engine parts? I liked and subscribed, great video!😎😎
Thanks! Engine parts are very hard to find. Mostly e-bay. Used parts in good condition.
Did the pipe bondo crack?
Ha! Funny you ask. I was gonna leave that pic out because it's a little of a 1/2 aced repair and I wasn't too proud of it - but yes! So far so good. The metal was in really good condition outside of being dented so it's holding nicely and no delam or cracks or anything.
Where did you get the yellow decals?
Back when I did this job there was a website a guy was running call "flashredbikes" if memory serves me correctly. He sold me a decal set. I can't tell you if he's still running the site or not. You'll have to google it and see if you can find it.
Where did you find the plastics
DC Plasics: SKU: HON-PK-1983XR500R $230 minus the tank. I kept the original plastics but they are not that great and beyond repairing into nice condition. The kit from DC is OK - looks good. You have to make your own mounting bolts for side panels and the front fender is kinda floppy but it's the only set you can find I think. Yellow decals not installed nor included. I think I got a new tank from CLarke if I remember correctly.
Did you end up painting the plastics?
No - plastics including tank are all aftermarket. I did save all the OEM stuff in case I ever sell the bike or whatever. They were pretty faded. I started by trying to restore the tank but it just wasn’t going well so I just replaced all of it.
@@paulhaines5755 Where did you get the aftermarket plastics
DC Plastics if memory serves me. A kit is the way to go. Very inferior to OEM for sure but not too bad. You'll have to punch holes in the fenders and get creative with side panel mounts to make it look nice. As for the tank, I simply don't recall. It might have been DC plastics but I kinda don't think it was. Side panels for these bikes are gold. If you actually found an OEM in good shape it would cost you a small forture - especially muffler/right side. I kept all my old plastic but it's not really that good of condition. I figured if I ever sold it maybe someone would want it.
ok I do remember - the tank was a clarke from JGT or someone like that. Pretty decent quality. I like it. No oem but not bad.
You should do my 82 xl500r.
What was the cost?
I paid $150 for the bike. I think I stuck something like $3500 into it.
@@paulhaines5755 I love it, I just got a 82 a few days ago for 700 and I’m following in your footsteps now. Do you know how easy it is to mix parts from different years on the xr series or transplanting parts from the crf?
Hmmm - that I am not sure of that. I mostly stuck to part numbers from the parts list specifically for this bike. I heard rumors of a spreadsheet that someone put together to help cross reference parts from year to year but I never used that resource so you might hunt around for that.
@@paulhaines5755 what do you believe was the most important part of your rebuild or the part you didn’t think would be as important to the whole process as you thought? Gasket material? OEM parts? Sanding/polishing tools? I’m just getting ready and need to know what not to forget until I need it
Are you getting into engine work or mostly cosmetic stuff?
How much did it cost to do the whole rebuild?
It was pretty outrageous. Keep in mind this bike was very thrashed. The engine needed almost everything so by the time I got done with that I was in too deep so I had to finish! It was between $3500 and $4000 I do believe.
If I did another bike I'd get one in better shape for sure and save some $. This project interested me because it was in such bad shape. I wanted something like this to really learn as much as I could and get a thorough picture of all that's involved from A to Z.
@@paulhaines5755 I have an 84 XR 500 that I am debating on restoration. I believe it would also be in the same $$$ range. Would you do it all over again?
@@SeanMolby If you have a tight connecting rod and good engine I probably would restore it. If you have any issues with the connecting rod then I wouldn't do it. Here's why: The top bore on the rod does not have bearings and is generally the first thing to go if the motor has ever been oil starved or is just plain used up. You cannot and I repeat cannot find new or aftermarket conrods for these bikes. I found one just by 100% luck and I think it was the last one left on earth! A loose conrod will cause issues with new rings seating and you'll have a noisy oil burner in no time. You can pay big bucks to have the conrod modified to a XR600 but it will cost you mucho. Parts are pretty hard to find. Really no new engine parts are to be found outside of pistons and rings and some stuff like that. OEM plastics in decent shape are non-existent. You'll have to go aftermarket with plastics and they are not as good and require a machinist level of home-made mounting brackets to make then look decent. Trust me - they don't just bolt on! If your plastics are in decent shape and you can refurbish them, it's a lot of elbow grease but worth it to save the OEM. With that, I'd say if you have a bike that's in pretty decent shape and has a pretty good motor, go for it! If it's beat to heck and has a oil burning engine that needs a lot of stuff, I'd go find something easier to work on such as a newer 600. If you like a big challenge then it might just be for you... (That's why I tackled it). Hope this helps! Ask for my e-mail if you have any more questions. I know this one inside and out.
@@anthonyquintanar1501 What are you needing help with? @paul haines, might be able to help also.
I have one of these and it's the best bike I ever had .
The forks are the best on the planet , you sit in this bike not on it so comfortable
Awesome! yea, as a youngster I always dreamed of having an XR500. I came across a few over the years that were kinda over priced and the wrong time for me. I bought this on at a yard sale on a spur of the moment decision and tackled it. It was a BIG project but I fulfilled a couple dreams. One was owning one and the other was rebuilding a poor condition bike to the best possible condition I could do.
Llo tengo la 7 la sucesora de esa
Music Sucks...….
Thanks!