At the outset – before the restoration

XT500 restoration project

This is what it looked like before the restoration began. You can view more images in the gallery on the right, or if you are using a small device it will be below.

Oil level – no oil on dip stick, can’t remember what it was last time I fired it up.

Engine turns over, good compression, measured by leg.

Good amount of rust, evenly distributed around the bike. Notably bad on the top of the forks, the clocks, battery box, parts of the carburetor, several areas of the frame and just about every nut, bolt and washer.

Chrome parts flaking, pitted or completely rusted, especially seat strap bolts and brackets, headlamp rim and tail light back plate. Corrosion and flaking paint to alloy parts such as the triple crown yokes, engine fins and top end.

Slow puncture in front tyre (Michelin). Tyres showing age with some cracking to walls (rear Bridgestone). Two spokes loose (heavy duty stainless steel).

Exhaust shows sign of rubbing from the rear knobbly.

Brakes work, all cables seem serviceable.

Deceased battery, killed a long time ago but this bike will run quite happily without one as long as you don’t need things like the horn, indicators and brake lights. Final drive chain worn out and sprockets not far behind.

1980 parts OEM:

  • Engine and frame
  • Speedometer (Km), Tachometer
  • Yokes / Triple clamps
  • Fork boots
  • Seat base (600mm) and strap
  • Air box
  • Petcock
  • Battery box and spare spark plug box
  • Wheel rims and brakes plates
  • Bash plate
  • Foot pegs, side stand
  • Foot brake pedal, shaft and brake linkage parts
  • Kick start and gear shift lever
  • Switches
  • Head light and brackets
  • Front indicators (not fitted) handle bar mounted
  • Rear mudguard/fender (needs complete restoration)

Earlier model parts OEM:

  • Forks from 1976 or 1977
  • Front mud guard with mud flap 1976 (mounted incorrectly)
  • Side panels are white 1979 shape or earlier (should be black)
  • Inner mudguard is off a 1976 and melted
  • Swing arm 1976 with broken front chain guard mount
  • Rear light assembly should be rectangular lens not circular
  • Carburetor from 1977-78

After market parts:

  • Oil temperature gauge dip stick
  • Handle bars and grips
  • Barkbusters
  • Long range tank stainless steel and cap
  • Exhaust BSM
  • Dual oil feed to valves
  • Cam chain adjustment cover (stainless steel or aluminium)
  • Heavy duty stainless steel spokes
  • Hagon rear shocks
  • Custom seat cover and cutdown foam
  • Various nuts and bolts requiring 13mm spanner

Missing parts (in addition to replacing those above):

  • Original fuel tank, aluminium required
  • Rear indicator signals
  • One rear reflector
  • Side reflectors
  • Chain guard
  • Speedo cable guide rubber damper
  • Tool box

Things done in 2001 that may or may not require work (max 3000 miles since then):

  • Powder coated swing arm, front and rear hubs
  • Heavy duty stainless steel spokes
  • Wheels and swing arm bearings
  • Exhaust

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