Das XL500 Forum

Should the end with the tighter coils be at the top or bottom?

embarrassing question, but can anyone tell me where the brake wear indicator should be positioned?

The dot on the brake arm lines up with the arrow on the brake panel, so I assumed the arrow on the brake wear indicator would do the same?

thanks Gunnar, and the 2 small holes in the side of the tube can face in any direction?

does it have to be replaced with the 2 holes lined in a specific way?

does anyone know how much needs to be left sticking up for it to go into the bearing case and stop it rotating but not so far as to restrict oil flow?

I couldn't get it to come out with the above method, but I found another way. Get a screw that just fits inside the hole enough to bite onto the tube but not damage it. Blow down onto the hole for a few minutes with hot air gun so that the aluminum expands more than the steel. A few tugs with the sl...

thanks guys.
90236-MN8-000 seems to be unavailable too but at least its another to look for on ebay

Hi, is there a clutch lock nut from another Honda bike that will fit? CMSL lists them for € 5.50 (90235429000), but they haven't got any in stock at the moment. I took a gamble and bought an 18mm one off ebay for a HONDA CB500X 2013 (90236-MGZ-J00), but the socket size is much larger and I'm not sur...

sorry for any confusion, I meant welding/grinding the solid pin to make it slightly longer, not the hollow one. I looked at several undamaged crankcases on ebay, and all of them seemed to have the pin only raised by about 1mm. The hole in the crankcase is manufactured too deep and the hole in the be...

I think the previous owner of mine had bolted together the crankcases with the pin not located in the bearing case hole. The result was that it pushed down and through the bottom as you describe. I managed to buy another set of undamaged PD02 crankcases off ebay. I did notice whilst looking that the...

thanks for the guide Gunnar. It's hard to see how much of the 'set bearing pin' needs to stick up into the hole of the needle bearing case. Can I ask what sort of length should go into the hole to stop it rotating and how do you stop it from sliding back down? It would be handy to know the same for ...

I stumbled onto a post here once covering this subject but have spent ages trying to find it again. I think one suggestion was a nail with a lip ground on the end, It was pushed inside the hole and then a screw to wedge it before pulling out with pliers. If anyone knows the name of the part for me t...

sorry, are you saying that the FT sprocket is wider than the XL one, but the output shaft are the same length on both bikes. They cut the groove for the fixing plate in a different position to allow for the wider sprocket. The two washers that you mention are put between the sprocket and fixing plat...

Germany have got to win. Our matches have been embarrassing. Like watching a school football team in comparison.
Germany 2 England 0

screenshot.png there was only 1 washer and it was at the opposite end of the shaft to where the drive sprocket would be. I'm wondering if the extra washer might just be a mistake by whoever worked on the gearbox. does anyone know the actual length of the XL shaft and FT shaft so I can measure to se...

hi Gunnar, I live in England in a county called Hertfordshire (40 miles north of London). I had an XL250 field bike when I was 18 ( https://www.youtube.com/watch?v=rHTZStrHQL8 ). I'm 56 now and saw a white 1982 XL500R on eBay and decided to buy it as I weigh a lot more now and think I need the extra...