Restoration of Motorcycle Cylinder Head Year 1982 - Honda XR 500 R - part 1.

Honda XR 500 R repair series
Hi.
This video shows - step by step - restoration of damaged
cylinder head.
Sandblasting - thread repair - painting - milling.
. . . for more interesting videos click ,, HERE "
/ @paulxchannel

[@redtobertshateshandles]

The old 500 wheelstand days. Great times.

[@paulcrombach7262]

I've repaired a couple of these heads myself. All the threads are always damaged because people overtighten the bolts. The reason you had to fit those threaded sleaves is because those bolts are M7. Somehow Honda in all their wisdom decided that they wanted to use this strange size for just a couple of the bolts. For the 2 bolt holes next to the cam journal in the middle of the head it is best to drill a bit deeper and have the threads a bit lower. There are some cases where that part broke of when tightening the bolts. Looking forward to the cam journal repair!

[@5tr41ghtGuy]

As the brits would say, that head is thoroughly knackered! Kudos for being able to bring it back to life 🙂

[@Afro408]

Or as the Aussies would ‘It’s Wallaby Edward’ 😉

[@ingeebeltoft]

Happy owner i am. XL 500 R in top shape. She runs like hell. Only one thing - tiny but irritating oil leak. Coming from the left front cylinder bolt. I ordered gasketkit and then start head / Sylinder off. Lovely having this old great working lady ❤️😎

[@Todestelzer]

You have to make a video in 20 years if it’s still working ❤

[@kennethjanczak4900]

Really nice repair job.....great to see a bit old school machining , instead of always cnc.... Cnc is great, but old school require some passion and soul... Thanks for taking the time to make the video and share it.

[@Zimbiker]

Really Love your work.❤️ Can't wait for valve job.

[@par4par72]

I bought this bike new hold over in 83. Love it. I left it up northeast, couldn't get it deep south.

[@lasdiralfreedom]

I really like your work. so I imitate you a lot, hopefully it will continue to be an inspiration

[@rorge007]

Work looks great, but the most important part of the job is repair the cam shaft bearings in the head, replace or repair the cam, recut the valve seats on the valves and in the head. Helicoils and making adapters awesome. Plane the head great.

[@PaulXchannel]

kzbin.info/www/bejne/qmmsqad5fJKfe5I

[@PaulXchannel]

kzbin.info/www/bejne/ppO1XpWff7mmaJY

[@BikerBenny]

after all that you used the same valve guides? Awesome machine shop! I'm getting a rod pressed on my crank and new valves and guides and seats machined on my 93 xr650l

[@ats-3693]

Awesome old bike, I'd love to find one of these again now.

[@Dimisrr]

Great work as always!

[@crozwayne]

love the Norton head in your intro Paul

[@vwivancc]

I cant wait for part 2. Regards from Mexico.

[@GB-el4mj]

Nice one. I just ripped my 84 apart for complete restoration. I found bent exhaust valves and it still ran like a top and had tons of power.

[@smcsumo]

What great skills and knowledge! 👏👏 Respect👌💯🔜🔝

[@josielheringer2319]

Muito bom excelente muito profissional 🇧🇷

[@redtobertshateshandles]

I bought an XR200 one time like this bike. Stripped threads x 12 or so. Ahhhh.

[@_zzpza]

Nice work as always! I look forward to seeing the cam journals repair. Weld and line bore?

[@margarita8442]

weld with tig

[@doughboy1966]

Absolute beast of a motorcycle

[@kittenfat2207]

Awesome video. It’s crazy how many of those threads are mangled! I love this type of work, and hope to get into machining at one point 👍 What did you study for this type of work?

[@minasretifica2566]

Perfect my friend, what an art your service. I work with motorcycle grinding here in Brazil. I'm subscribed to your channel. Cheers ...thanks

[@heathmurphy3735]

I am starting to think you could start with a pile of aluminium chips and build an engine....well done sir.

[@nazoe83]

*Jarang upload video, sekalinya upload video selalu jadi inspirasi 👍*

[@iurii-wind]

Master! 🤝👍👏👏👏👏👏👏👏🔥

[@davyw.8659]

is that a crack in the inlet next to a valve seat ?

[@theboat9311]

I have subscribed in the hope that this is a full rebuild series. I am just about to start pulling my 81 xr 500 appart and see whats wrong, person i got it from said it leaks oil really bad. So i guess it somthing in the bottom end. I will be watching and saving these videos for rewating when i get to these parts

[@jamesal0]

now the hard bit - cam tunnel

[@nunesmotos351]

Seus ekipamento é muito profissional top dez de mais

[@ezequielsilva2709]

Muito bom 👏👏

[@shane9338]

cool vid :) those valves are case hardened and will fail in short order if you grind and reuse them

[@purebloodheretic4682]

Great Work! Your are a Great Machinist! Do you think Re-machining & Re Bushing the Cam Tunnels could be Feasible? & do you think it could it be done successfully with a Lathe similar to yours? I I have 2 XR600r Motors that have Heads that have Badly Damaged/Worn Can Tunnels rendering them Useless! You Can't buy a New OEM XR600 Head anymore, they simply aren't being manufactured any more! This seems to be the "Achilles Heel" of many a RFVC Honda Bikes when there is an Oil Starvation issue Via Negligence eg; Low or No Oil - Forgetting to prime the oil pump or even Mechanical failure! This could Save many Bikes that have the same Common Fault - Wrecked Cam Tunnel Valve Trains! I think this Single Problem has claimed many XR600's - Also the tiny External Oil line seems a bit inadequate if you have a Performance Modded XR! If these Heads could be Repaired it would save a lot of Xr's from the Scrap Heap! -Cheers 👍

[@nunesmotos351]

Trabalho super dez feito com hellicoi

[@zardportugal]

Top job.

[@user-ly9rl7us5n]

ロッカーアームの経たりは、バルブクリアランス取っても、広めになっちゃうのよね。 ハイカム程陥る現象。 綺麗にレストアして、エンジンの元気を取り戻すのは、 地道な作業するからの報酬的な事ですね。

[@AcidVFR400R]

Would you not vapour blast rather than sand blast ? The finish is amazing, Made me wish I had build one 10 years ago

[@anonymously241]

Gud job PhoL 👍

[@girthy10incher23]

I had an 82 XL 500R in this same condition, be aware those stock valve seats are prone to cracking

[@davidchacon3812]

Do you rebuild these motors entirely? Pretty hard to find people whole will touch these motors, especially people who know them.

[@wilsoncamilodasilva516]

Meu deus o cara ainda pega paquimetro pra conferi valvula amassada kkkkkkk rapaz.mete.a lixadeira nisso ai pronto todo jeito vai trocá mesmo

[@ivanc251]

GREAT

[@ivanretifica2580]

I hope one day to work with you...👍🙏

[@megametico794]

Olá eu tenho uma xl 250 83, uma dúvida 😅 eu poderia colocar o bloco de uma xl 500 em uma 250? Seria compatível?

[@BreathingFire]

14:40 mmm... magic!!

[@hugojaimericaurtemoncayo5020]

Por favor … Una pregunta … En el minuto 6:04 se nota un orificio ubicado entre los dos escapes Cómo tapó ese orificio ? Porque la motocicleta debe sonar demasiado fuerte

[@15LoydsCustom]

💪💪💪

[@gertkristensen6451]

👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍

[@vwivancc]

A great and wonderful work! Where are you from? Regards from Mexico.

[@pedrofernando176]

👍✌

[@aluheinzel]

top 1aaaaaa

[@rolneimoraes7715]

Boa Noite amigo k Belo trabalho muito bom . Uma pergunta c o amigo pode m ajudar tenho uma falcon 400i e não consigo tirar o vazamento do cilindro não tem ok lide abri 3 vezes o motor o vazamento continua antes arrancava os prisioneiros e agora troquei a camisa por causar dos prisioneiros pois vazou denovo cera k e pouco combustível porque ela é muito econômica faz 31 km com litro ,ou pela posição dos prisioneiros pode estar muito fraco o aperto

[@sandrorodrigues9384]

🏆⭐⭐⭐⭐⭐👏👏👏👏👏

[@rolneimoraes7715]

Coloquei junta original e não fez diferença c os prisioneiros fosse igual o da 500 k vc mexeu aí acho k era melhor cera

[@abdullahodabasi2139]

How much does it cost for this replenish?

[@user-ej4sh1bw1s]

😀

[@raystevens687]

so what about the damaged camshaft and the cam cradel those are still damaged

[@PaulXchannel]

In future videos

[@gerardharings9963]

you did not show how to repair the camshaft seating ( bearing)

[@PaulXchannel]

kzbin.info/www/bejne/ppO1XpWff7mmaJY

[@Baby_driver_m]

How can I contact you?

[@yoceflkorti3800]

لكن لماذا تتأخر في نشر مزيد من الفيديو

[@helmutweidemeier7940]

Hi Paul, i need your help for my cylinder head. It has a valve torn off and demolished the combustion chamber. How can I contact you?

[@PaulXchannel]

Thank you for your trust. I do not provide this service to the public.

[@helmutweidemeier7940]

@@PaulXchannel that is a great pity

[@robertoburromiapanino2659]

Not sure if you aware but a couple of those threads on the top side are 7 x 1.0mm as standard? Oh, the bike you show at the start of your video is an '81 model XR500RB not the '82 RC. Also, the XR500 from '81/'82 had a reed valve on the inlet of the head, this head is either an XL or '80 model XR500.

[@PaulXchannel]

It is possible. Now they are M6 :)

[@robertoburromiapanino2659]

@@PaulXchannel I think the two bolts adjacent the right side exhaust valve were up spec'd to M7 to stop oil leaks, the torque values are increased accordingly . Only done on the reed valve equipped 81/82 models I reckon. Do it while it's apart mate, good videos btw.

[@redtobertshateshandles]

I think this m7 stuff is b.s. I've never seen an m7 bolt and I've worked on a few bikes.

[@robertoburromiapanino2659]

@@redtobertshateshandles Well Fred clearly you haven't worked on squat, try working on some more with your fing eyes open! Earlier '79/80's had em in the triple tree too. The honda has 2 m7 bolts in the rocker cover for your information. I just did a quick ebay search for a stainless bolt set and hey ho, you won't believe it, it mentions the m7 bolts. Well who''da thunk it eh Fred... goddam clown. You could thank me for making you smarter but I've yet to believe you actually learned something.

[@c__TattinhNhi]

It's pretty much damaged

[@h-j.k.8971]

Naa, too much emphasis on trick filming and editing instead of getting on with the project, almost to the point of boring.

[@PaulXchannel]

Ok

[@h-j.k.8971]

@@PaulXchannel 👍

[@larrywarner9314]

I don't use heli coils that much theses days threaded inserts is much stronger with lock tite 638 green

[@grantfuller2016]

Heli coils are stronger than standard “ aluminium threads” ( so long as you use the correct length ones ) . Pretty sure a couple of the “ repaired “ threads in this video are actually 7mm from factory ( and it’s not an XR head , it’s XL or FT , but they are all pretty similar)

[@redtobertshateshandles]

Nothing wrong with Helicoils but not overtightening is better.

[@gerhardengelbrecht9679]

Gonna hit bearings with the sandblasting in the head.. the oil makes the sand come loose that is inbedded into the casting.. did it with cam covers on a engine and lost the engine..

[@simonkirkness2573]

I don’t understand why you paint the head before you do the machine work ?

[@anthonynicholich9654]

Air cooled 4 stroke hondas of the early eighties pre RFVC and RFVC had a ton of valve train top end problems. All 3 other Japanese brands Yamaha Kawasaki and Suzuki were better.

[@redtobertshateshandles]

Suzuki 4 valves weren't much better. Oil we used was dinosaur and used to burn with the heat.. XT500's were OK because they were built more ruggedly. They were still prone to old oil though.

[@rocksolidhugo]

Helicoil's for amateurs

[@davidbernardi3393]

What do you use?

[@pisunets]

Why did you waste my 1 minute of time in the beginning?

[@damianbrennan2258]

Where r u located Paul

[@flaviaalmeida930]

brother you are a very professional beast I wish I had the opportunity to work with you it would be a pleasure 🦾🔨🔩⚙️Brasil 🇧🇷