Re-used ZX12 switch blocks on XL500

I also have these ZX12 switch blocks left over and will use them on the XL500. The left switch will be used exactly as is, but the right one will be re-tasked so the kill switch will be the headlight on/off and the start button will be the kill button.

ZX12 chain guard re-used on XL500

This is one more part that is getting reused. I recently parted-out my ZX12 as the crank had spun a bearing and I still have quite a few odds 'n' sods left. So I thought, if we can make it work then we will! After a bit of cut and shut it works well, and you will always know where it came from!

XL500 stripped bare & ready for wiring installation

Everything has been removed that is necessary for us to add the wiring. Still a long list of parts to procure though. Indicator, headlight ears, chain guard, exhaust heat shield, horn, mirrors, speedometer, battery and pillion pegs? Also resprayed the rear shock springs last night.

Steering bearing troubles

I noticed there was a fair degree of movement in the steering head, so I thought I would switch out the bearings from the XL250 as they are the same. The ball bearings are loose and not caged, and so I discovered on pulling the triple clamps out of the 500 that there was one ball missing top and bottom! So, regrease the races and put in the missing bearing top and bottom and it should be fine. The trick is to use lots of grease so that the balls stick to the races and do not fall out upon re-assembly.

Rear axle modifications

Bottom image shows rear axle arrangement bodge up. Somebody welded on a piece of angle iron to attach the chain adjuster to. It does not work, so I ground part of it off and attached a different style of adjuster. Also there was no split pin hole perpendicular through the axle, so I drilled one to accept a split pin. I also contacted PPSR to check there was no money owing on the vehicle and to make sure it was not stolen, all clear. The VIN plate is missing so I contacted Transport WA with the chassis number to see if it had been registered before, and it has, so getting it re-registered will be straight forward.

XL250 tank now fits XL500

With a few modifications, the XL250 tank now fits the XL500. I still want to remove most of the paint-work from the tank, while leaving the decals on the sides intact.

Free electrical parts

Thanks to the guys at 66 motorcycles, who gave me these bits 'n' pieces for the XL500.