Okay, let’s talk about getting this old 1980 Honda XL185S back on its feet. It’s been quite the journey, let me tell ya.
Getting Started – The Bike Arrives
So, I managed to get my hands on this XL185S. Looked pretty rough, honestly. Been sitting for who knows how long. Dust everywhere, flat tires, you know the drill. First thing I did was push it into my garage, get it up on a stand, and just walk around it. Had to see what I was really dealing with.
The Initial Check-Up
I started poking around. Checked the oil – looked nasty. Tried to turn the engine over with the kickstart, felt like it had compression, which was a good sign. The chain was rusty as heck, and the brakes felt spongy. Electrics? Didn’t even bother trying them yet. Knew this was going to be a strip-down job.
Tearing It Down
Alright, time to get dirty. I began taking things off. Seat came off easy. Tank next – drained some nasty old gas first. Then the side panels, fenders, exhaust. Started labelling wires with tape, even though the harness looked pretty simple. Took lots of pictures with my phone so I’d remember where stuff went. Eventually, I had the engine out of the frame. Felt good to have it broken down into manageable chunks.
Engine Work – The Heart of the Matter
Focused on the engine first. Pulled the valve cover, checked the clearances. They weren’t too far off, adjusted them anyway. The big job was the carburetor. That thing was completely gummed up. Took it apart piece by piece, soaked it in cleaner, scrubbed all the little passages and jets. Put it back together with a new gasket kit. Changed the oil and the oil filter, of course. Put in a new spark plug too.
Frame and Chassis Cleanup
With the engine out, I gave the frame a good look. Some surface rust here and there, but nothing too serious, thankfully. Got out the wire brush and sandpaper, cleaned up the rusty spots, and hit it with some rust converter and a bit of black spray paint just to protect it. Cleaned all the grime off the swingarm and linkage.
Wheels, Brakes, and Suspension
The wheels needed attention. Tires were cracked and hard, so they had to go. Ordered some new dual-sport tires. While the wheels were off, I cleaned the hubs and checked the wheel bearings. They felt okay, so I just repacked them with grease. Pulled the brake shoes out – yeah, they were shot. Got new ones. Cleaned out the brake drums real good. The front forks felt a bit soft, so I drained the old oil (yuck) and put in fresh fork oil. Cleaned up the rear shocks, they seemed okay for now.
Sorting Out the Electrics
This part can be a headache. I cleaned every single electrical connector I could find with contact cleaner. Checked the wiring harness for any obvious breaks or frays. Put a battery charger on the old battery, but it was toast. Had to get a new one. Hooked everything back up, crossed my fingers, and turned the key. Hey, the neutral light came on! Tested the headlight, taillight, blinkers – most worked after cleaning connections and replacing a couple of bulbs. The horn even gave a weak little beep.
Putting It All Back Together
Okay, the fun part and sometimes the frustrating part. Started bolting things back on. Engine went back into the freshly cleaned frame. Connected the exhaust. Mounted the carb. Routed the cables and wiring harness carefully. Put the gas tank back on (after rinsing it out thoroughly). New chain and sprockets went on. Mounted the wheels with the new tires. Bolted on the seat, fenders, side panels. Everything got a good wipe-down.
- New tires
- New battery
- New chain and sprockets
- New brake shoes
- New spark plug
- New air filter
- Carburetor rebuild kit
- Fresh oil and filter
- New fork oil
The Moment of Truth
Filled the tank with fresh gas. Turned the fuel petcock on. Pulled the choke. Took a deep breath and gave it a kick. And another. And another. Took a few tries, fiddled with the idle screw a bit. Then, it sputtered to life! Man, what a sound. Let it warm up, adjusted the idle. It actually ran pretty smooth. Felt awesome.
First Ride and Final Thoughts
Took it for a quick spin around the block. Shifted through the gears, tested the brakes. Felt pretty good! Still needs some fine-tuning on the carb, probably, but it runs and rides. It’s not a showroom bike, got plenty of scratches and dings, but it’s alive again. Was a lot of work, late nights in the garage, greasy hands, but totally worth it to bring this old Honda back from the dead. Simple bikes, these old XLs, fun to work on.
