Das XL500 Forum

thanks for all of your advice. Engineer rang today and said the +.5 rebore went perfectly and the groove is no longer visible. I was surprised at how cheap it was too at only £46. I mentioned that I have new NOS valves and NOS valve guides and new guide seals. Engineer said that Honda deliberately m...

when I disassembled the final drive transmission shaft, I found that there was an extra thrust washer and the low gear has been scoring a large circle inside the crankcase. I read somewhere on here that the FT500 shafts are slightly longer than the XL500. Do youi think it been replaced with FT500 an...

is there a place you guys get your pistons/rings from in case I need to get a +.75?

I took the cylinder and old standard piston, a new +.25 piston and a new +.5 piston to the machine shop. The +.25 just dropped straight through the bore with too much slop. Engineer felt a slight groove in bore then said they'll rebore/hone for the .5 and see if the groove is gone. If not, I can't r...

thanks

would the above measurements be ok to just hone the cylinder and put my NOS standard piston/rings in?

the piston only has 'IN' so I assume is standard size.

Piston measures:
88.62mm (TOP), 89.01mm (MIDDLE), 88.99mm (BOTTOM)

cylinder bore measures:
89.29mm (TOP), 89.30mm (MIDDLE), 89.32mm (BOTTOM)

I'm new to this, where would you measure it, the pin?

thank you Kristian.

Do you have a link for the repair manual as nothing comes up for me on google?

Does anyone know the upper and lower limits of diameter for each of the 4 stock size pistons?

Is there a marking somewhere on the piston to show what size it is?

sorry, I meant Musket sell them as a matching pair.

not nos, the exhaust is Marving (Italy) and the downpipe is Musket (NZ).

I bought them in that order, but Marving sell both as a matching pair. I should have bought them both from Marving if I'd have known that in the first place.

thanks guys, that's just what I wanted to hear.

I won't need to paint the exhaust and down pipe peter as they're new

I've stripped the engine down to bare metal to be painted in semi gloss 2k black paint.

I'd prefer the barrel and cylinder to match too, but realise that most people use VHT paint for those parts.

Does anyone know if the 2k will take the heat OK or should I use VHT?

they both came out using the vice method. I heard the initial 'crack' and then by twisting left/right as I pulled upwards.