Big TX500 project, any help appreciated!

Here’s a side by side. Bike on left is non running parts bike. Bike on right is running and will be fully restored:) it’s a mix and match game. Notice the exhaust on left in near perfect condition compared to exhaust on right which is slightly beat up.
 

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Here’s a side by side. Bike on left is non running parts bike. Bike on right is running and will be fully restored:) it’s a mix and match game. Notice the exhaust on left in near perfect condition compared to exhaust on right which is slightly beat up.
That’s the way to do it!
 
Tested the engine again but outside this time. You can clearly see the rust/soot on the ground coming from a rotted exhaust. Good thing I have a donor bike with a healthy exhaust :) I almost have the wiring harness removed. After that it will be time to remove the engine, clean frame and possibly get it powder coated.
Later.
 

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Been busy … whew!! Gave her a much needed bath and started on the easy parts first :)
 

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Gas tank attention. After restoring many over the years, here is my protocol:
Step 1- pressure wash inside with soap
Step 2- CLR inside for about 20 min
Step 3- rinse
Step 4- soak with Evapo-rust
Step 5- rinse
Step 6- acetone rinse
Final step- line with Red-Kote
I’ve cleaned up some bits and waiting on fresh cap gasket
 

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Well… the update is that I really have not had much time recently to do anything other than restore the gas tank and chain.
Gas tank was really stubborn with all the rust but managed to clear that out and put a nice liner in it.
Chain was also rusty …. Nice soak in Evaporust and it’s looking better. Just waiting on some lube.
That’s it for now. Will hopefully have more time this weekend to tackle her!
Oh shoot… almost forgot but I am going to try the single carb route again. I know some of you don’t like that but I’m not too pleased with original carbs. Will see what happens.
 

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I'm not sure trying to save an old original chain like that is worth the time and effort. They weren't very high quality items to begin with. If you want a nice, quality regular chain, spring for a standard D.I.D., about $40.
 
I'm not sure trying to save an old original chain like that is worth the time and effort. They weren't very high quality items to begin with. If you want a nice, quality regular chain, spring for a standard D.I.D., about $40.
Good point and I did think about that. I’m cheap though :)
 
Well…. I was just curious to see how/ if she would run on a single carb and no issues except she’s idling fast. I just purchased a cheap Chinese fake mikuni carb so did not expect it to run perfect.
I will keep tossing around my options with the carbs .
Anyhow… pushing forward, will purchase some new tires and continue to teardown and clean things. Engine runs strong which was my main concern.
 
Lol….. yes, I will get pic’s tomorrow. I do have a high idle issue too , therefore suspecting air leak.
So….. this is just a prototype manifold using pvc. I have a welding shop making similar design using stainless pipe. Again…. Cheap Chinese carb but bike starts right up. Just tinkering around. The high idle could be the original intake boots that will need replacing.
Tank is ready…. New petcocks bolted right on.
 

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No surprise… the original intake boots are toast. Will order new and maybe go with an aftermarket aluminum manifold with rubber boot. Hopefully this will fix the high idle :)
 

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Single carb manifold will be completed by welding shop tomorrow.
Small gas leak detected from a petcock screw going into the tank… no big deal, will fix.
New tires ordered. Lots to be done but will be next week.
 

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Here’s a pic of the stainless manifold sent by the welder. Nice work! The inner lip on the single pipe(carb) side will have to be reamed out. Other than that, this will be good. New tires are in. Taking a short vacation then when I return will definitely get back to restoring this beautiful bike :)
I have the precise specs I will post tomorrow, if you wanted to tackle building this. Of course it only applies to a tx500.
 

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