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Thread: 1978 SR500E refurb

  1. #1

    1978 SR500E refurb

    So, rather than keep adding to the technical posts, I thought I'd start a thread dedicated to the strip down and as close to stock as possible rebuild.

    If you haven't seen, the bike was a one owner 1978 SR500E 2U8, one of the first 500 into Australia (based on frame number).

    It's owner (still his bike in my mind) succumbed to a brain tumour on Christmas Eve last year, less than 3 months after diagnosis. His daughter is a dear friend of mine, my father lent me the money to save the bike from my friend's idiot brother who wanted to cut it up.

    So far I've gotten it started, flushed the oil and tidied it up.

    Now I've started to strip it down, there is a little rust on the frame from a leaking rear master cylinder. Currently it's a pile of bits, with the frame sitting on the ground.

    Because it was so well looked after, the swingarm pivot had been greased, and I was able to remove it with tapping from a 12oz hammer!
    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  2. #2
    Overall, I'm expecting to just have to renew seals, rubber bushings and rebuild brake hydraulic components.

    The wiring loom looks ok, only one section was dodgy twisted together. I'll have it tested, but most likely we'll build a new one whilst it's apart, given the age of the loom.

    The headlight surround and front fender have holes in them and need replacing. Everything else chrome needs a polish.

    The only challenge is to find an exhaust that is very similar to the original. Any tips welcomed, or if someone Oz based has one they want to part with, let me know.
    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  3. #3
    FORUM SUPPORTER
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    Dec 2015
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    Nice to see you going the stock route. Yamaha did a great job with the look of the bike.

    I'll have a similar project in the future. Once the Camel Hump is done I'll focus more energy on the 80 Eggplant. I want it as stock as possible mainly
    so I can get collector insurance which is less than $200 a year.

    Keep us entertained with lots of photos.

    Steve

  4. #4
    I'm sure I left a bike around here somewhere

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    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  5. #5
    Senior Member duke b's Avatar
    Join Date
    Dec 2015
    Location
    NJ/NYC, USA
    Posts
    229
    Nothing the Pink Floyd toolbox can't handle!
    1979 SR500F / THE BLACK SPIDER (Pictured here in 2015, and here in 2014)


  6. #6
    Quote Originally Posted by duke b View Post
    Nothing the Pink Floyd toolbox can't handle!


    I'll take a photo of that one next time I'm in the shed.

    Technically I've got 5 small toolboxes. One's a screwdriver set, a 3/8 socket set, a small one suited for my boat (1978 fibreglass with 1983 60hp Yamaha), another suited for our camper trailer and that red one I've had for 20+ years with random tools, screws, bolts, connectors and anything that might come in handy one day.

    Taken all 5 to have all the tools I need
    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  7. #7
    Junior Member davedunsboro's Avatar
    Join Date
    Jan 2016
    Location
    Dunsnorough SW of West OZ
    Posts
    18
    The headlight surround and front fender have holes in them and need replacing. Everything else chrome needs a polish.

    The only challenge is to find an exhaust that is very similar to the original. Any tips welcomed, or if someone Oz based has one they want to part with, let me know.[/QUOTE]

    I've had lots of success buying parts off Vic motorcycle wreckers over the years
    They used to break lots of SR400s & most of the bits are a straight up fit
    Ito in japan is a good contact too
    Cheers Dave

  8. #8
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    Toolbox as promised.
    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  9. #9
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    So this is the carburetor that is on the bike (bench).

    Is it the original?
    1978 SR500E 2U8

    Confused about your frame number?
    http://xt500.free.fr/technique/numerosr.html

  10. #10
    Senior Member MadMax's Avatar
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    Dec 2015
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    Whitehaven Cumberland
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    Quote Originally Posted by red dragin View Post
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    So this is the carburetor that is on the bike (bench).

    Is it the original?
    Should look like this http://www.siue.edu/~rsutton/SR/mikuni.htm

    Yours looks more like an early XT500 carb to me.

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