Main aim was at first just to get it running, get an original tank, restore the seat and deal with the rust. As time passed I quickly realised that just wasn’t going to cut the mustard, I needed to do more to get it registered here in Italy. So the aim changed to get it looking at least closer to a 1980 model, deal with the extensive corrosion and get it registered for road use in Italy.
I wasn’t attempting to do a 100% nuts and bolts restoration job, just wanted to get the grin on my face again.
My aim changed yet again when research (and the TT500 XT500 forum) showed me that the European and Australian models had different colour schemes (amongst other things). Before this realisation I was convinced I had the wrong wheel rim colour, an expense I wasn’t convinced I should take.
No worries though. Decided on the original Australia, USA, Canada and South Africa styling of “New Yamaha Black” rather than the European version with a white tank, black bash plate and gold wheel rims. The UK version appeared in the James Bond film, “For Your Eyes Only” in 1981, with added machine guns.
More about the model details later. My frame and engine numbers match and begin with 3H7, this was for Australia and Canada. The States version started with 3H6, looked basically the same but there were slight changes.
So now I could use the wheels and bash plate that I had.
I also aimed to convert to 12V and electronic ignition replacing the 6V contact points and really poor lights. I set myself a target date of not later than spring 2021 which will be 32 years after I first bought it. It will be 41 years old. I am reaching that deadline as I write and I still haven’t finished.
Existing Spares:
- OEM cam timing chain, new still in packaging
- Speedo cable guide but missing the rubber damper
- OEM oil dipstick
- OEM front indicators (handlebar mounted)
- Bought 1980 forks found on Subito (€280 + shipping €20)
Initial thoughts on where to start:
- Update my tool kit and buy some of the specialist tools to make life easier.
- Get it running first to confirm oil is circulating and then drain it out while hot.
- Dismantle completely so that the frame and parts could be powder coated.
- Clean up and powder coat/paint yokes, clocks and all brackets.
- Clean carb and check internally.
- Inspect valves, cylinder, top end, repair or replace any worn parts, hone or re-bore if necessary.
- I was quite confident that gears and the bottom end were fine and would not need to split the crankcases.
- Paint engine after cylinder and top end assembly – wasn’t sure if to powder coat.
- Fit Rex’s Speedshop 12v conversion, electric ignition kit and battery, my least favourite part of this project is the wiring and electrics.
- May not install indicators unless it is a legal requirement in Italy, quite happy using my arms as I always have).
- Find 1980 aluminium tank, not too damaged, repair and paint if in the wrong colours.
- Buy new seat foam and cover.
- Clean up front mudguard and side panels, maybe source black side panels.
- Replace tyres and inner tubes (front tube has a very slow puncture in tubeless).
- Remove BSM logo from tail pipe, repaint.
- Chain guide/case saver, around front drive sprocket.
- Replace drive chain and sprockets. Change from 17/42 to 16/43 and fit case saver. Standard ratio is 16/42.
- The 1976 inner mudguard is a mess and needs repairing or replacing with a 1980 version.
- Repaint rear mudguard and search for a rectangular tail light replacing the circular one.
First order:
- 12V kit from Rex’s Speed Shop
- Rubber Cap for Fork Top Nut 21036, 1 Piece
- Chain Slider Swing Arm (Ring)
- Aluminium Chain Guide (Case Saver)
- Chain Guard/Chain Case (large type)
- Mounting Kit for OEM XT500 Chain Guard Item
- Rear Fender Extension (aka inner mudguard)
- Replica Rear Reflector, Red, Round, 55mm
- Rubber Pad at Outer Fork Tube (Cable Guide), OEM
- Front Brake Lever black, OEM
- Chain Tensioner Block, Round Top
- Screws for Seat Mounting Brackets, OEM
- Seat Mounting Set (Seat to Frame, Allen Screws M8)
- Rubber Damper Side Cover Lock
- Rubber Dampers for Tacho-/Speedometer
- Engine Oil Valve, (stop valve)
- Bracket for Rear Indicators
- Indicators, fits Front and Rear, ‘E’-marked, Black
- Rubber Grommets, cap for rear indicator thread
- Front Fork Top Yoke Screw
- Screws for Meter Bracket
- Replica Front Fender ‘Clean White’
- Air Filter, OEM Reference # 583-14451-00
- NGK Spark Plugs BP7ES
- Air Filter Oil, 1000ml
- Gasket for Oil Sump, OEM Reference # 583-13414-00
- Gasket Left Crankcase / Generator Cover, OEM
- Gasket Right Crankcase / Clutch Cover
- O-Ring (e.g oil filter cover, intake valve cover)
- Seat Strap Bolts, Stainless Steel, Chrome
