this was soo helpful! I am about to partake in this endeavor myself. one question though, is it possible to upgrade the 79 xl500s (the one i have) from a 6v system to a 12v????
Glad it helped! I read that some have simply changed the regulator/rectifier to a 12v unit, which leaves 6v on the ignition system. That would be the simple way, but I’m not sure what they’re doing for the headlight, as that’s on its own wire (I think). The stock xl500 stator might already be putting out 12v...check your stator’s output on each wire, before the regulator. Another said they swapped the stator with one from an 82 xl250 which apparently bolted right in, but in that case it sounds like you’ll have to change the cdi as it’ll mess with the ignition timing. Read up on some forums, good luck!
I know this is an old question, but just in case anyone else wants to know and sees this; yes, you can just fit a modern reg/rec to an XL500S to get 12V. The alternator output to the CDI is unaffected. The headlight may also be on its own direct output from the alternator in which case it can also be left alone, on mine I wanted it buffered from the battery so re-wired it and put in a 12V bulb. You may not have many amps though so LED tail light etc. is recommended. Been running mine like this for 15 years since I changed it.
I have an 82. When I started, the inner hub was flush inside the outer edge of the basket. Now the inner hub shoulder is just outside of the basket end. I put it together and it is way too tight. Is there an orientation on the shaft for the basket and inner hub that I missed?
Not that I recall, not sure… Is it possible you didn’t put the correct friction ring at the very back, where it’s supposed to clear over the two large washer/rings?
Is it possible to do a video call with you about my bike? I took my casing off my bike to redo the gasket seal and a washer and a kind pin looking thing just fell out. I've never owned a bike before I have the 81 honda xl500s and i have no clue where those parts go back on at.
Best bet would be find the parts diagram. I often use Bikebandit. Google “1981 Honda xl500s bikebandit” and the diagram should show up. If you can describe the parts better (and size) I might know.
@@themotofirm one part was the little round bearing ring. Another part is a bigger sized washer. Then the last part looks like a nipple with a flat end.
Sounds like the clutch rod and bearing, and maybe the lock washer. Definitely important to have all those in the right spot. You can email a photo to themotofirm@gmail.com
Hmm, mine has quite a bit of side-to-side play but shifts fine. It’s possible your shift fork is bent, but hard to say without seeing it/taking it apart.
I just bought a 1982 XL500R and will use your video as a guide! Thanks so much!
Good job. I just bougth a Honda Xr 1979, ir Is good to know how the engine inside
Great, helpful Video! Thanks a lot for sharing this! Regards from Germany
Wow thanks .not so hard step by step .I've got an 81 xl500s just bout it for 200 bucks .so at least ther is videos bout it
Killer deal on a fun bike, hope this helps!
Shood I go with a stock cluch pack or the pricey one thanks
I’d just do an oem or good quality aftermarket (like Vesrah)
Thanks for the excellent video.
Right on, hope it helped
this was soo helpful! I am about to partake in this endeavor myself. one question though, is it possible to upgrade the 79 xl500s (the one i have) from a 6v system to a 12v????
Glad it helped!
I read that some have simply changed the regulator/rectifier to a 12v unit, which leaves 6v on the ignition system. That would be the simple way, but I’m not sure what they’re doing for the headlight, as that’s on its own wire (I think). The stock xl500 stator might already be putting out 12v...check your stator’s output on each wire, before the regulator.
Another said they swapped the stator with one from an 82 xl250 which apparently bolted right in, but in that case it sounds like you’ll have to change the cdi as it’ll mess with the ignition timing. Read up on some forums, good luck!
I know this is an old question, but just in case anyone else wants to know and sees this; yes, you can just fit a modern reg/rec to an XL500S to get 12V. The alternator output to the CDI is unaffected. The headlight may also be on its own direct output from the alternator in which case it can also be left alone, on mine I wanted it buffered from the battery so re-wired it and put in a 12V bulb. You may not have many amps though so LED tail light etc. is recommended. Been running mine like this for 15 years since I changed it.
I have an 82. When I started, the inner hub was flush inside the outer edge of the basket. Now the inner hub shoulder is just outside of the basket end. I put it together and it is way too tight. Is there an orientation on the shaft for the basket and inner hub that I missed?
Not that I recall, not sure…
Is it possible you didn’t put the correct friction ring at the very back, where it’s supposed to clear over the two large washer/rings?
Great video, thanks
Is it possible to do a video call with you about my bike? I took my casing off my bike to redo the gasket seal and a washer and a kind pin looking thing just fell out. I've never owned a bike before I have the 81 honda xl500s and i have no clue where those parts go back on at.
Best bet would be find the parts diagram. I often use Bikebandit. Google “1981 Honda xl500s bikebandit” and the diagram should show up.
If you can describe the parts better (and size) I might know.
@@themotofirm one part was the little round bearing ring. Another part is a bigger sized washer. Then the last part looks like a nipple with a flat end.
I wish I could put a picture on here of it cause I'm about to tear it back down and see if I can figure it out
Sounds like the clutch rod and bearing, and maybe the lock washer. Definitely important to have all those in the right spot.
You can email a photo to themotofirm@gmail.com
My bike gear pedal on the other end comes out a little bit and it can't engage gears unless I push it inside what may cause the problem?
Hmm, mine has quite a bit of side-to-side play but shifts fine. It’s possible your shift fork is bent, but hard to say without seeing it/taking it apart.
Drop the Jutter spring and seat and just add a normal sized clutch plate
Its the 1st thing youll do once you graduate to a Dyna or Softie.....
Great !!
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