Thumper Club Forum
Technical => Bike Problems/Questions => Topic started by: guest1540 on August 03, 2012, 08:48:07 PM
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Hi,I am new to this great site and I have just bought an xbr500. The bike has been layed up for the past 20 years (in Sligo - Ireland) and although only 7k on the clock, the frame and engine need a lot of cosmetic work. I intend to build a cafe racer. I have wire wheels and a xl600r barrel and piston on the way. I want the bike to have a bit of punch but remain an 'easy to live with' bike. Can anyone recomend a mild cam and appropriate carb- or should I just re-jet the origional? Thanks for all the info already shared on the site.
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hi did you check out project progress ,have a look at xbr rebuild .where are you based tommy
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Depends on what you want to spend :-\
This article is a few years old and I don't know if you can still get the bits but it will give you some ideas.
http://www.champsclock.com/gb500hu.htm (http://www.champsclock.com/gb500hu.htm)
You can get the original cam reprofiled. An XL600R CDI is supposed to pepp it up a bit - more ignition advance. You really want to ask Joolz on this forum, he's recently finished a project on a quick XBR and probably give you some pointers.
Welcome to the forum!! ;D
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Hi tommy, I based in Newry in Northern Ireland ('keep her light Joey Dunlop' country) I'll check out the project section tomorrow - thanks.
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Hi SteveC, that's a great article you recomemmed on tuning an xbr and definately gives me food for thought. Have you a contact for re-profilling the cam?
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Try Phil Joy, excellent engineer.
Joy Engineering Motorcycle Camshaft Specialist
Tel: 01279 730682
The Workshop, Ryes Lane, Hatfield Heath, Bishops Stortford CM22 7BS
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Depends on what you want to spend :-\
This article is a few years old and I don't know if you can still get the bits but it will give you some ideas.
http://www.champsclock.com/gb500hu.htm (http://www.champsclock.com/gb500hu.htm)
You can get the original cam reprofiled. An XL600R CDI is supposed to pepp it up a bit - more ignition advance. You really want to ask Joolz on this forum, he's recently finished a project on a quick XBR and probably give you some pointers.
Welcome to the forum!! ;D
Hi Onelung anything you need to know let me know, and I will give you a few pointers
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Hi Joolz, sorry for the late reply. Just back from Gallipli in Turkey. The Aussies have claimed this First World War battle as their sacrifice alone but I was supprised to find that thousands of English and Irish guy's lost their lives their as well.
I have fitted a 600 barrel, ported the head and I've ordered a 1986 xl600 CDI from the states. Joy engineering no longer have a profile cam for the xbr but do have one that is very close? I need to manufacture an exhaust (I'm looking at a range of stainless exhaust bends and pipe for sale on the net) and decide what carb to use, any advice on these issues? :-\
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Im surprised that Joy engineering doesn't have the XBR cam blank as I had my cam reground there less than 6 months ago the XL cam is similar, perhaps there is a suitable profile there, he also has the HRC profile cam. As for exhausts, there are plans for the RS600 pipes on the internet they will give you more go. Carbs are up to you, either standard rejetted or 40 -42 Mikuni flatslides, good but expensive, or Amal 38-40mm cheaper but a bit basic, but do flow well at full throttle.
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Thanks for that info Joolz. The guy at Joy Engineering explained that they had used the XBR blank for a one off special job? Have you any knowledge re the wiring modes required to fit the XL600 CDI to the XBR. The only site I can find relates to a GB500. While very well written and detailed, the guy states that the GB CDI is A/C powered and the XBR as D/C so I'm reluctant to follow his instructions in case I fry my new unit.
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My xbr,like the xl,is a/c powered.A battery terminal became loose on my bike once,and all the electrics vanished,except the ignition.I only realised the terminal was loose when I tried to indicate and nothing happened.The bike was still running perfectly.
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The XL 600 R cdi plugs straight in with no modifications. I think the 1 off special cam my be mine :) sorry about that. Kent cams have XBR cams in stock, have a look on there web site, they offer 2 different grinds
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So your the culprit that got the last Joy Engining cam!!!!!. That's OK because from what I've read about your bike you'll make better use of it than me. Thanks for the contact, I'll try Kent Cams. Have you any more info about the site for the exhaust plans, I can't find it under "RS600 exhaust plans"
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Send me your email address and I will attach the RS600 exhaust design for you
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Hi Joolz, thanks for the RS600 exhaust plans. Not sure if I can reproduce them accurately but they provide a great general template so thanks again for taking the time to send them.
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no problem :)
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we did some work on a xr600 engine i think they are similar, i have a couple of xr600 cams which are in good condition,on the carb side you buy a crf 450 carb they have pump jet and are fitted with hot start,you can make a manifold up to change from oval to round then fit a xj650 carb rubber this brings it out straight ,do away with the air box and fit a filter ,this is what we did to a xr engine for twinshock motocross
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And there is also Mikuni TM 40 with an adapter for XBR.
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My xbr calf racer project is nearly finished so I'll post some pictures soon. Main problem at the moment is when I plug in my xl600 CDI unit and push the starter button - the 10 amp relay fuse blows? CDI unit number is MG2 CF476A. I thought this was a straight swap but it keeps blowing this fuse for some reason. Any views on this problem.
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Weird, does it kick over and start ok. Does the starter motor turn over at all or will the fuse blow without the starter turning. Have you got a good earth between the starter and the frame?
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Hi Joolz, I was hoping you would come to the rescue. The fuse blows as soon as the starter button is pushed - starter does not turn over. I didn't try to start her with the kick start but I presume the wiring is ok because when I refit the original CDI unit she fires up on the starter first time? There is a discussion about this problem on the GB500 site but the guy talks about removing a green/white wire to stop the fuse blowing. I can only find a green wire on the xbr loom from the CDI so Im reluctant to follow his instruction.
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I dont know what the problem might be. Kick it over with the xl cdi fitted to confirm the the cdi unit works and the bike runs ok.
Dont go removing wires without knowing what they do. Read my current post on cdi boxs, on page 3 there is a diagram showing the pin outs and the corresponding wire colours. I didnt encounter this problem on my XBR as the starter was knackered and I always kicked it
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Ok I'll try the kick starter approach tomorrow Joolz. Excuse my ignorance but where can I find your discussion on CDI units.
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There is a 'boost' function on the XBR CDi that gives a bigger spark when the starter is engaged, it could well be causing issues on the XL CDi.
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Ok I'll try the kick starter approach tomorrow Joolz. Excuse my ignorance but where can I find your discussion on CDI units.
Its on the chatter general discussions page, open my post cdi box, open the link, and scroll down to page 3
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Good article Joolz but although the wiring details on page 3 correctly states that the unit has a 2 and a 4 pine connector, it then identifies seven different colored wires connecting to it?
I fitted the xl CDI and tried the kick start as you suggested - the engine fired up first time!!!.
I would still like to use the starter though so I will have to figure out what is blowing the 10A fuse.
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I'm sure there is a real obvious answer to this but - can anyone explain how I upload photos?
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Bike finished and MOT'd this morning. Although the weather over here in N.I. has been wet and cold I can't help taking her out every chance I get. I love riding this bike - it's everything I hoped it would be. Ill post pictures in the project section.
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Can't upload photo's to the Project site - so here goes to this section???
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Can't upload photos - even one! Refused stating that the file size is too big??? Any advice?
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You need to resize the photo to 800 pixels, I use this free website to resize...........http://www.webresizer.com/resizer/
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Here goes - again!!!
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Hi, just finished my xbr500 rebuild. I would like to thank everyone who posted info about similar projects and a special thanks to those who offered advice and guidance about my specific project.
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That looks really good. Well done
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Thanks Joolz, coming from you that's big praise indeed - even though it looks like you probably did get the last special xbr cam in the universe!!!!!!!!!!!