Das XL500 Forum

Our government has just introduced E10 fuel at all petrol stations. The news said that it has been in Europe for quite a while.
They also said that the fuel will damage older vehicles by ruining seals or the inside of petrol tanks.
What do you guys do to prevent this? Is there some kind of additive?

For future information, the 2 bolts (#25) on the Honda diagram E1-CYLINDER HEAD COVER - part number 957000608000/957010608000 are incorrect. These bolts are M6X80 and should be M6X60 (taking a 10mm socket).

The correct part number is 95701-060-6000

No need for an answer now. Problem solved.

Next question. The haynes manual says....... 'turn the selector drum until the plain lobe of the stopper plate is almost vertical, then fit the detent stopper arm and spring...... the roller on the end of the stopper arm should engage the small neutral recess in the plate.' Is E definitely the neutr...

I've fitted and torqued a nut in place as I needed to get on with the rebuild.
Incidentally, Using a piece of chord to fit the spring was really easy with no chance of causing damage.

well the new kickstart spring has arrived (thank you Peter).

One question though. The haynes manual shows a nut with torque setting that doesn't exist on either my bike or on the Honda XL500R diagram at CMSL.

Can anyone explain please?

Thanks Peter. So when they're screwed in there are meant to be 2 tall studs, 1 medium and 1 short :zustimm: Yet another problem was found during engine reassembly. The kick starter return spring had a fracture. Whilst waiting for the new one to arrive, I started assembling the powder coated frame to...

problem number 2. The 2 longer stud bolts screw in fully until they are 180mm above the surface. The 2 shorter stud bolts screw in at different levels (165mm and 175mm above the surface). Stud A screws fully in, to the point where it wont go in any more (even though the hole is open at the bottom)....

All of the new seals and parts fitted back into the left crankcase cover fine. There was a problem though with the right hand cover. I tapped a new pin into the clutch lever mechanism thinking it would be drilled to the right depth, but it seemed to go in a bit far for my liking. Do you think the sp...

The engine has finally been sprayed in 2K satin black, and now its time to rebuild and show pics as I progress.
Never done this before, so please forgive the constant questions in advance.
I already have 2, but first a picture of the painted parts.

Peter, looks like you're correct. There should be 13 bolts but I have 14. Gunnar, Thanks for taking the time to take all of those measurements. It took me ages, so I'm guessing it did the same or you. All but one of your cover measurements match mine closely, but 7 of the cylinder head thread measur...

thanks peter and gunnar. I measured the threads in the head and the shaft lengths from the cover yesterday. I've figured out which bolts are needed but the allen one kept confusing me. Now I know why. I'm part way through zinc plating, so have to keep popping back to the shed, but I'll compare my me...

Can someone with original Honda bolts on an XL500R please look to see what is in position B?

A standard bolt head doesn't fit against the casting and and allen bolt only goes in at an angle

https://images.cmsnl.com/img/partslists/honda-xl500r-1982-c-belgium-e-1-cylinder-head-cover-decompression-cable_big3IMG01166116_ab76.gif I want to replace the allen key cylinder head bolts for the original Honda ones. After looking at the confusing link (some bolts have 2 numbers), I ordered what I ...

thanks.
Haynes manual said top but the honda manual shows a picture of the tighter coils (tapered) at the bottom.
Mine isn't tapered, so it was confusing