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Old 02-23-2020, 06:13 AM   #1 (permalink)
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‘78 Honda XL100- get it rideable build

I picked up an old 78 Honda XL100 from my neighbor for $200 that he said “ran when I parked it”. He also said the gas tank leaked, so if all true, I knew what I was getting into. Meh. I have spent 200 on worse things, so it was worth the gamble. Right?

There some hack on it and the rest seems to be original, so not too bad of shape overall.
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Old 02-23-2020, 06:19 AM   #2 (permalink)
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I cleaned it up, which surprisingly, came out looking good. I squirt some carb clean down the intake tube and after figuring out their ghetto 3 position toggle switch, I got it to start. Nice. Now I know it will run.

I pulled the tank and carb to see what I was dealing with and like that one chick in school, it wasn’t pretty.
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Old 02-23-2020, 06:26 AM   #3 (permalink)
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The seat cover is toast, along with various other hacks and the tires are probably original.

Here’s some other pics. Yes, it's a 6v system.
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Old 02-23-2020, 06:31 AM   #4 (permalink)
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Tire and it might need a chain
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Old 02-23-2020, 06:38 AM   #5 (permalink)
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So, off to the interwebs to find parts. So the easy stuff was Kreem gas tank cleaning and sealing kit. Amazon had the tank cleaner, carb, petcock, chain, seat cover, tire tube and rear tire. The front tire was somehow also made of unobtainium. After an extensive search, Summit actually had it, or could get it. Kind of weird, but whatever.
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Old 02-23-2020, 06:48 AM   #6 (permalink)
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So the easy part first. Toss the new carb on and spark plug in, add some gas and vroom. She runs. Sweet this was also a good time to reroute the throttle cable correctly.
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Old 02-23-2020, 06:56 AM   #7 (permalink)
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Now to the fun stuff. The tank already had a liner I. It that was coming apart which is why the tank was leaking again. The liner looked old, so I’m sure it was done 20 years or so ago. I used the Kreem cleaner from the kit and nuts and bolts to bang things around in there. After that didn’t work very well, I ended up using lone needle nose pliers and surgical forceps to remove as much of the old liner as possible. Then added the new tank liner.

The petcock was “glued” to the old tank/liner and had to be.......forcefully removed. I had a new one so no big deal, till the new one wouldn’t fit. I ended up CannibalIzing the 2 too make the old one work. Sorry, no pics on that.
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Old 02-23-2020, 06:59 AM   #8 (permalink)
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Once the tank dried and I made sure there were no leaks, I installed them and ran the engine for a while. It smoked up the place, but that just means it’s working right.
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Old 02-23-2020, 07:04 AM   #9 (permalink)
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Rolled it old school for changing the tires. Hell, I even forgot my tire spoons at work, so I used flat head screwdrivers to get it done. I haven’t done that in a while.

Don’t forget a tire band.......or electrical tape.
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Old 02-23-2020, 07:13 AM   #10 (permalink)
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Time to put on a new chain. The old was was pretty rusted and probably original. I cut the old one off with a saw zaw, then measured the length I wanted and used my chain tool to remove the proper link. NOTE: make sure use remove the correct link or the master link will not work. NOTE2: always install the master key lock with the back side facing forward in rotation.
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Old 02-23-2020, 07:18 AM   #11 (permalink)
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And you know I have ridden it already, right???
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Old 02-23-2020, 07:28 AM   #12 (permalink)
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On to the seat.

The seat foam is in good shape, but the cover was hammered. On the plus side, Honda used the same seat for just about every bike back then, so a seat cover was easy to come by.

I’m not much of an upholstery person, but there are tabs on the seat pan that you pry out and the cover just comes off.

Once I heated up the new cover in a electric ice chest I have (also heat), the cover was very workable. I stretched it over the pad and pan, then locked it into the little tabs and tapped them closed with a hammer.
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Old 02-23-2020, 07:31 AM   #13 (permalink)
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I could do more to it, but to be honest, it runs and rides well, so no need to go overboard. Hell it starts on the second kick when cold and first kick when warm. Can’t ask fo too much more than that.

I have just under $600 tied up into it including purchase price. This will be fun to putt around the farm with and the wifey to learn on.
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Old 02-23-2020, 09:35 AM   #14 (permalink)
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Kick ass!

The very first dirtbike I ever rode in my life was a 78' XL100. I had so much fun on that little thing!
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Old 02-23-2020, 03:56 PM   #15 (permalink)
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That’s pretty cool.

To be honest, it has more pep than my Grom (125cc). Hell of a lot of fun to ride too.
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Old 02-23-2020, 03:58 PM   #16 (permalink)
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I love little Hondas

Sweet project
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Old 02-23-2020, 04:05 PM   #17 (permalink)
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I have a Yamaha “Trail 90” out back I got for $20 and built some points for it from leftovers and got it running.

It’s totally complete and last registered in 1978, and a project for when I get bored, which is probably 10 years away.

7k original miles and have the OG pink slip.

Cool project.
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Old 02-23-2020, 04:47 PM   #18 (permalink)
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I still have 1 complete '78 XL100 and about 3 in parts. Keep an eye on the carb flange where it mounts to the head I've seen several develop a small crack and start sucking air. For the chain did you install a 428 or 428H?
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Old 02-23-2020, 04:57 PM   #19 (permalink)
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Quote:
Originally Posted by Pukemaggots View Post
I still have 1 complete '78 XL100 and about 3 in parts. Keep an eye on the carb flange where it mounts to the head I've seen several develop a small crack and start sucking air. For the chain did you install a 428 or 428H?
Thatís cool.

Will do

I used a did428hgi-120rj, from what I have on my notes.
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Old 02-24-2020, 07:06 AM   #20 (permalink)
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I forgot a few pics. I did get a battery strap and air filter. I was going to use the stock air tube, box and filter, but the tube was so hard, I couldn’t get it back on the box and carb, so I just used a universal foamy one. Not original, but this is not exactly a museum piece.
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