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Thread: Another Gem - 1978 Honda XL 75

  1. #1
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001

    Another Gem - 1978 Honda XL 75

    Went to a friends about 1 1/2 hrs away to work on my jeep transmission and noticed a bike leaning against a spruce tree in his yard. Turns out it's a 1978 XL 75 with only ~2000 kms (1200 mi) on the clock. He told me it's a friends and tinkered with it a bit but couldn't get it going. Ironically, he doesn't hesitate to split a tractor for a clutch but really doesn't like to work on this sort of thing. It didn't look too promising at first covered in sap and grime with the seat pan growing into the tree bark as it's been there so long. I confirmed the piston moved, and seen old gas still in the tank so potentially intact. Looks fairly complete, seems to shift OK but but unfortunately missing all signal lights and both side covers are broken. I did find the original owners manual in a pouch inside one panel which is a bonus. I filled the cylinder with marvel mystery oil as a precaution and drained the motor oil which had a teaspoon of water in it and grossly overfilled. The best part is I paid $100.00 for it and can potentially register it for the road at some point.

    What it needs initially at this point:
    2 tires
    Header pipe is corroded through in one area - easy welding fix
    Check for spark
    Check compression
    Clean carb
    Needs a chain and maybe sprockets - cut off the old chain as it was seized solid and piano spring tight
    Hand grips
    Throttle handle
    All cables
    Seat pan needs patches but still serviceable
    Seat foam and cover

    This is going to be a slow resurrection as it's getting into outdoor activities now and shop time limited to rainy days.
    Attached Thumbnails Attached Thumbnails IMG_0401r.jpg   IMG_0395r.jpg   IMG_0385r.jpg   IMG_0384r.jpg   IMG_0393r.jpg   IMG_0391r.jpg  

    IMG_0403r.jpg   Seat Panr.jpg  
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  2. #2
    Join Date
    Apr 2011
    Location
    Mexico
    --
    9,003
    The go to bike for dads that didn’t want their kids learning to ride on RM/KX/CR/YZ 80’s. You’re gonna hear a lot of “I had one of those” at the annual parade.

    That over-tightened chain is period correct as it was typically the first suspended bike for most, so they tightened the chain like they would on a Bronco, or a bicycle
    It sucks to get old

  3. #3
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001
    Started tinkering a little starting with the carb, yikes......nasty inside! I managed to get everything freed up and blown out so I'm expecting at least marginal success before I pop for a rebuild kit pending the bike is worth the effort. Good news is that there's an oily (albeit disintegrating) foam filter element in it which makes me feel better.

    Now on to spark. Question, this unit uses a small battery.......do I need a battery for it to produce spark? I'm guessing not as most ATV's I've dealt with can be kicked/pull started when the battery is completely dead as long as it's carbureted. Please advise if this isn't the case as I'm not at all experienced on bikes.
    Attached Thumbnails Attached Thumbnails IMG_0583r.jpg  
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  4. #4
    Join Date
    Jul 2010
    Location
    Arkansas
    --
    2,196
    It shouldn't need the battery to start.

    Those early Honda XL's just had a battery for the street legal bits. They had to have a battery powered rear light by law that way if it was on the side of the road and not running the rear light still worked.

    The battery was also for the turn signals, instrument lamps, and horn. The headlight should still be AC, which only works with the engine running.

    I haven't had one that vintage, but what I said is pretty much par for the course on US model XL's. Ignition and headlight operate on AC, the rest is DC.

    It probably has 6v battery/system. You can upgrade that to 12v for modern compatibility.
    Last edited by ATC King; 06-29-2023 at 10:35 PM.
    The story of three wheels and a man...

  5. #5
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001
    ^That definitely all makes perfect sense ATC, thanks for this! I wouldn't expect Canadian models to be set up any differently either. I was told it had spark by the guy who sold it but you know how that goes.......by the look of the flywheel area I'm guessing no. I'll pull it and clean/adjust the points and see what happens.

    Cheers,
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  6. #6
    Join Date
    Jul 2010
    Location
    Arkansas
    --
    2,196
    Out of curiosity I checked Partzilla to see if it had points...yep.

    The points and condenser (capacitor in new terms) are still available new through Honda but that's about $50.

    The six volt battery isn't saving any money over a twelve volt one either.

    Depending on your plans and budget it may be better to convert the system to twelve volts and install an electronic ignition. The bolt-on iggys I found for it can get pretty expensive though. Of course, since you only paid $100 for it, basically anything it needs is going to blow the purchase price out of the water. Would be a good idea to get it running and sorted out then go from there.

    That'd make a great RV bike for toodling around the camp.

    I know I'd replace or remove the front brake shoes before riding it any. Something that's sat that long has a pretty good chance of the brake lining delaminating and locking the front wheel. Front drum brakes have other issues besides stopping power.
    The story of three wheels and a man...

  7. #7
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001
    Definitely going to take small steps to see if it's viable to get this back to road worthy condition. I've been informed by the boss that this is going to be sold so I'm thinking parts wise I need to keep it below $1500. I'm not concerned about labor costs as It's my hobby. It will be gone through front to back and will take your advice to heart.....thanks :-)
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  8. #8
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001
    Update: It was pretty simple to get spark, found a broken ground wire and cleaned/adjusted the points. When checking valve adjustments, it appears to me that someone has been in this thing as why else would there be assembly lube on the valves and on the end of the cam shaft? I hooked up a temporary fuel source and spun the heck out of it with a drill/socket on the flywheel to see if it will fire. I got a couple of inconsistent pops back through the carb. I'm wondering if it's 180 degrees out? The best I can get for compression is ~75lbs even with the cylinder warmed up with a heat gun and wot. Think I'll pull the stator plate and check valve timing next then pull the jug to check the piston/cylinder clearances.

    Note: I also pulled the exhaust off to make sure it was clear and I tried to get it to make noise with the exhaust off completely.
    Attached Thumbnails Attached Thumbnails IMG_0591r.jpg   IMG_0589r.jpg   IMG_0592r.jpg  
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  9. #9
    Join Date
    Jul 2009
    Location
    South Florida
    --
    6,722
    Flip the flywheel over and make sure the advancer dots line up . Very common for them to be installed 180 degrees out .
    78 atc 90/180cc Dickson Full Suspension
    76 ATC90/180cc Nicholson
    77 atc 90 Dickson Full Suspension
    84 KLT 110/123cc Powroll Racer from 80s
    87 atc 125m stock
    84 atc 200x Curtis Sparks
    84 atc 200x Powroll My race bike from 80's
    83 atc70/108cc Powroll blue Xmas Special
    81 atc185s HP-ATC full suspension

    Performance Shop is Open PM me for Service

    My Feedback http://www.3wheelerworld.com/showthr...ck+shortline10

  10. #10
    Join Date
    Jun 2010
    Location
    Cold Lake, Alberta, Canada
    --
    3,001
    ^I'll have to look into that as I've never encountered such a thing. I suspect the information is in my manual.....hopefully :-)
    Trikes
    1970/71 US 90 (Aquarius Blue)
    1970/71 US 90 (Future Project)
    1972/73 US 90 Camo Project (110 Big Bore)
    1972/73 US 90 Green
    1977 ATC 90 w/83 110 motor (Fugly)
    1982 ATC 70
    1983 ATC 70 (Ladybug)
    1973 ATC 70

    1965 Marketeer 3 Wheel Golf Cart with 1986 Honda 250 drivetrain

    TF 2015

    Other
    1983 Honda Z50
    1978 Honda XL75

    Feedback http://www.3wheelerworld.com/showthr...ck-for-coopool
    http://www.3wheelerworld.com/showthr...k-for-coolpool

  11. #11
    Join Date
    Jul 2010
    Location
    Arkansas
    --
    2,196
    You may want to check out BAT if you haven't recently.

    The smaller XL/XR bikes are bringing relatively high prices. Not that you're building it to sell but if you work around a budget it may be an option if you decide to.
    The story of three wheels and a man...

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