Hi all, haven't been here in a while . Hope you guys can guild me in the right direction?
Question #1 what is a good gasket kit (name) for rebuilding?
Question #2 a rebore may be needed for my cylinder,What piston kit should I be looking at (Wisco ?, OEM?, or a other?)
Question #3 I'm Bidding on a complete good used head on ebay what would be top price for this kind of head ? ($150, $200, $250?....).
Question #4 I will be replacing the timing chain, what is a good chain (name) for my rebiuld?

If there is anything else you can add for info on my rebuild please feel free to help on my 1st rebuild. THANK YOU VERY MUCH!!!

Hi I rebuilt a 84 XR500R last year and here are my opinions
the gasket set I used was a NOS top end set I don't remember the brand but I have heard a lot of good things about athena gaskets.
As far as rebore and piston I went with a used oem the reason I didn't go with a wiseco high comp piston is because the RFVC xrs tend to over heat when you rebore and use high comp pistons, I think XLs run lower compression than the XRs so i don't know if it will be a problem for you or not
I cant say how much is a good price for a head or what brand cam chain, I did not replace my cam chain it was done by the the guy I got it from


keep us up to date on how it goes and pics are always good

Quinn, I bought a gasket set off ebay, sorry I don't remember the name, but it works fine. I used a Wiseco piston because I had one in one of the donor motors I was using. I would, however recommend oem since my bike tends to detonate a bit in warm weather. A lower compression piston shouldn't do that. I used a K&L cam chain. I seems to work pretty good. I believe that the supplier I used bought it at Sudco. I have no idea what a good price for head should be, I'm married. Troy341

That was funny...I'm married, good one troy.
So far I found a (VERSAH) gasket kit for $70?, ebay
(K-L) timing chain $80?, ebay
All I know on the piston part the origanal is 8.6:1 ratio 89mm bore from factory. reliabilaty is what I'm looking for.Don't need to over heat on the street,or dirt. Got side panels left & right side off ebay $56 with shipping used .I think that was a fair price & good condition .Hard to find pieces.
I'll keep you up dated on the head .
Thanks guys,if you think of anything else let me know.

I just checked and the gasket set I used was a versah set, it was only top end but I have no complaints with it

Watch the aftermarket base gaskets for the 500s..I had to replace the base and head on mine last week. Both had been blown for some time and I'm selling the bike (sold actually) so thought I'd better fix them. Anyway I was almost ready to drop the cylinder onto the base gasket when I noticed the oil hole on the gasket that is supposed to be clear was still covered by the perforated bit that I'd expect to be pre-removed. I thought it was darn slack someone selling gaskets like that. , missed a certain seizure by a whisker.

Be aware if you're doing or thinking of doing the Conrod it's a bit of a specialists job on those bikes. Hole needs to be bored through the oil thrower to get at the pin then the cut out bit needs to be welded back on. Not something the average mechanic or engineer knows about..They used to try and make you buy a whole new crank as opposed to just the rod before someone figured the boring trick out..

Thanks (Mr Miller & Horri) for that info ,that would of deffently destroyed a expensive top end rebuild with that oil hole capped off on that gasket .I will deffently check all the gaskets in the kit when I get it .Think I'll go with the VESRAH complete gasket kit.

Hi Mghty Quinn,
I have used this ebay supplier for gasket set for my xl 500s rebuilds before on several occasions and never had any problems at all and they are a great price.( and made in Japan. ) And no matter who the supplier you should always check all the punch holes and oil feeds are clear.

cruzinimage_co ( Feedback Score Of 5818)

As for piston I have used weisco a couple of times and always had a good result currently using a 95mm hi comp 10:1 piston. I have had this bike since new and has been rebuilt several times over the last 31 years and was on last oversize prior to the last rebuild and it was much cheaper to resleeve over size to 600cc weisco
Regards Rod.

Rod Rocket, any detonation problems with your high comp wiseco's? If so what did you do to rectify or do you just ride around the problem? Thanks. Troy341

Thanks (rod rocket) for the expert advice. Purchased the head off ebay for $125 (minus the cam) plus shipping $42 ,so for $167 I think it was a good deal.Now I think I've been talked into a Wisco piston kit ,from you guys.
What's first over size? .10 or .20 thou.from stock I'll probabaly have to have the cylinder bored out?
Hey Troy, what are you running for fuel in your bike, oxinated or non-oxinated?This could be part of your problem with the pinning.

have you checked with Xlintperformance? Dave Rhynehart? he does great head work and has lotsa parts.

Mighty, I don't think that the fuel is oxygenated here in the summer and I do use the highest octane I can. Any other suggestions are welcomed. Thanks. Troy341

Hi 341,
Yes when first run after rebuild I had detonation problems using 98 octane fuel the highest available at the pump here in Australia, I added octane boost from a performance outlet which raises the octane by aprox 7 RON it runs pretty well on that after a bit of fiddling. to get the mix right.
Regards Rod.

Hey Troy341, type in (Octane rating)- Wikiapidia this might give some better info on the octane rating of fuels , areas, alltiude, & companies .ect... May be more confusing than anything

Thanks guys, I apprecitate the help. Troy341