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Yes, it is that that easy to start a XR500. Except when it is not.
Yes, it is that that easy to start a XR500. Except when it is not.
You know, when the engine is flooded, when you are stuck in the mud, on a hillside, when the motor is too hot, when it is too cold, when it should f@#%&g start!
You know, when the engine is flooded, when you are stuck in the mud, on a hillside, when the motor is too hot, when it is too cold, when it should f@#%&g start!
My right leg bears witness...
My right leg bears witness...
It goes like this:
It goes like this:
"The FT500 motor is the same as the XR/XLS, with the bonus of electric start yeah? Let's put it in a dirt bike chassis and bob's your uncle."
"The FT500 motor is the same as the XR/XLS, with the bonus of electric start yeah? Let's put it in a dirt bike chassis and bob's your uncle."
If only it were that simple...
If only it were that simple...
Some have done it (almost?)
Some have done it (almost?)
No chain, did it ever run?
No chain, did it ever run?
Needs a creative exhaust
Needs a creative exhaust
Bash plate for deep sump
Bash plate for deep sump
Some visible differences between the FT500 engine and the XR500 (there are many more)
Some visible differences between the FT500 engine and the XR500 (there are many more)
Exhaust outlets are quite different.
Exhaust outlets are quite different.
XR500
XR500
FT500
FT500
This means that a XR/XLS exhaust header will not fit.
This means that a XR/XLS exhaust header will not fit.
XR header in FT head, no go.
XR header in FT head, no go.
FT brackets (top) won't hold XR header
FT brackets (top) won't hold XR header
The XR500 exhaust header, positioned as properly as possible fouls the starter motor.
The XR500 exhaust header, positioned as properly as possible fouls the starter motor.
All of this is pointing to a custom header as the solution
All of this is pointing to a custom header as the solution
Oil pumps are different
Oil pumps are different
Bodies are different, number of teeth
Bodies are different, number of teeth
Covers are different
Covers are different
Clutch covers are very different
Clutch covers are very different
XR500
XR500
FT500
FT500
A dirt bike has to have a kick starter, so let's get the best of both worlds.
A dirt bike has to have a kick starter, so let's get the best of both worlds.
But the FT500 engine cases has more surprises
But the FT500 engine cases has more surprises
Removing the sump extension also removes the oil filter system. In addition, the XR500 oil filter mesh cannot be fitted.
Removing the sump extension also removes the oil filter system. In addition, the XR500 oil filter mesh cannot be fitted.
Only the 1982 XL500R lower case will both fit the FT500 stator cover and provide the housing for the oil filter mesh
Only the 1982 XL500R lower case will both fit the FT500 stator cover and provide the housing for the oil filter mesh
List of parts needed for the conversion
List of parts needed for the conversion
- FT500 engine
- FT500 CDI
- Battery etc.
- Handlebar starter switch
- 1982 XL500R lower engine case (other models will not match the FT500 stator cover)
- XR500 clutch cover with automatic decompressor lever
- XR500 complete kick starter mechanism
- XR500 oil pump
- XR500 oil filter mesh
- 1981-82 XR500R rocker cover
- 1981-82 XR500R decompressor cam lever, spring , cable bracket and cable
- Custom exhaust header
- Gaskets, grommets etc.
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