1981 Honda XL500S Part 2: fuel tank rot and carb clean up

Finally had enough content to release part 2. a lot of time was spent waiting on some parts, waiting on cleaning the carb and figuring out a plan of attack to deal with the fuel tank rot.

[@burthammer2871]

For future reference I would avoid putting water in the tank and instead sacrifice small amounts of fresh gas to rinse out all rust and debris. Enjoying the series !!

[@markward6076]

Thank you for creating good content.

[@Garage2Trail]

Thanks for tuning in Mark! I appreciate it.

[@SDTriathlete]

I had to do the same procedures on the tank I had on my 1982 XL500R I restored. Had to braze some metal holes and added JBWeld epoxy as well.

[@daveallen8824]

FYI - on that mixture screw beside the bowl, that tab is a smog limiter - you might need to hack that tab off so that the adjustment is unlimited. They tend to be a bit lean.

[@Garage2Trail]

Ok, thank you for the info!

[@maxhenry9724]

Really want to tell you how much I appreciate these videos on the 500s. I am in the process of bringing a pretty nice 1980 that’s sit for 20 years in a guys garage back to life. It’s in beautiful shape has just sit and needs gone through. First time tackling something like this and watching you has made my journey a little easier! Would you please tell me what you are spraying into the cables as a lube and what you are using as a lube on the inside of the carb? And you have a new subscriber.

[@Garage2Trail]

I appreciate that and I’m glad to be able to help in any way! Good to know these are helping others bring these bikes back. I’m just using “deep creep” lubricant on the cables. They make specific cable lube but I was just using what I had on hand. Also for the carb, I was using gum out carb cleaner. Thank you for the sub!

[@shermantincher3417]

Just started watching your videos yesterday. Find them informative, and subscribed right away. Hope to do the same in the future. Not necessarily an XL 500. As far as your fuel tank was curious about the availability of after market tanks or even possibly an OEM tank from Honda for a bike this old. Good luck with your projects and will continue watching and looking forward to more projects to come.👍👍👍👍

[@Garage2Trail]

Thank you I appreciate the sub! Glad to be able to help out in any way. I didn’t look for an OEM one because I just assumed finding one would cost a lot but there is is still NOS stuff out there. I think there are aftermarket options too but I was focused on trying to save the one that was on the bike.

[@burthammer2871]

Also not sure how you'd feel about having a plastic tank as it would take away from the vintage look you're going for but check out clarke tanks. They make higher capacity tanks for all old bikes including yours.

[@burthammer2871]

I'm not trying to spam your videos lol but was that soapy water you were using in the ultrasonic cleaner ? If so you need to switch to a solvent to avoid any rust or corrosion that water would undoubtedly create. Just trying to help!

[@Garage2Trail]

That’s ok, I appreciate the input! Yeah just water and dish soap. Once they are pulled out of the ultrasonic they are blown dry and with an airline so there wouldn’t be any water sitting. Same with the fuel tank…once the vinegar was drained I just flushed it out with water, then sprayed with wd40 to prevent flash rusting. Then, as you said I usually flush with some gas before adding in fuel to run it. I ended up selling this bike at vintage days to get two more projects for the channel. These are great bikes!

[@Valterpenato]

Miracle😅

[@leftfordeadgarage4198]

I've got the same bike. 1980 honda xl500s. Also have 1979 xr500, 1979 xr250, 1980 xr250

[@1683clifton]

Mine had a plastic tank! 😅

[@Garage2Trail]

Was it aftermarket?

[@geraldwalker2209]

I have 2 and ascot 82