Das XL500 Forum

I used 'All Balls' bearings. I also purchased a piece of steel tubing from Ebay for £6 to use as a tool. It slide over the steering stem with a bit of wiggle room and was slightly longer than the stem length (I can get the exact measurements if you want). I did mine in the summer. I put the stem in ...

Belated Christmas greetings due to being away.
Thanks everyone for your help in 2022, and wishing you all a happy new year.

sorry, I haven't explained it very well. The link above is the wrong cap. However, If you ask the seller (or sellers on your ebay) for the same make but part number 749536, you will get the correct locking cap for the XL500R. :-D :-D :-D :-D :-D It fits perfectly and has a breather pipe connection.

WARNING-DO NOT BUY THE LOCKING FUEL CAP IN THE LINK!!! https://www.ebay.co.uk/itm/115611443219 I bought it for £11.50 with free postage, but it's too small. However, I sent the diameter of the original cap to the seller (57mm) and he posted a replacement cap which fits perfectly (part number 749536)...

I contacted Sklia on the post above, and he used 1mm cross sectional cable with no problems so far. I also contacted the person on ebay who sells new XL500R harnesses, and he replied with the following: 1. Wire cross sectional area in square mm is- 2.00mm 2. Outside diameter of wire & insulation...

Here's one, but too expensive in my opinion.

https://www.ebay.co.uk/itm/334066652423

I'll be making a post soon showing a simple guide of how I do mine with a shopping list of parts and prices.

Looks like mine.
I'm having wiring problems too at the moment.
I started repairing the faults but decided to just make a whole new wiring loom instead.

thanks. I'll post the final details and guide (with pictures) once it's finished.

My XL500R had electrical problems. Firstly, the rear brake light would only work when the hand lever was pulled, but not whilst using the foot pedal. I traced this to a faulty wire inside the loom. If it was bent back and forth, the light went on/off. After mending that, I tried to tackle a faulty i...

I had 2 pairs of crankcases. The sleeves on both were loose enough to slide out by hand. But I thought it was meant to be like this so as to allow the linkless timing chain to be removed?

Sorry, I have just noticed that you are referring to an XL250.
I should have mentioned that mine is a XL500R

nothing was attached to them on mine.

I had a similar job to do on my build. Here is the link.....

viewtopic.php?f=2&t=14648&p=126088#p126088

I used helicoil because tests showed it was the strongest and came in the different lengths needed.

Gute Nachrichten! Ich habe die Dekompressionskabel richtig eingestellt und jetzt ist die Kompression genau so, wie sie sein sollte. Wahrscheinlich zu viel, um mit meinen dünnen Beinen anzufangen.

Thanks Gunnar. I haven't had a chance to do any more on my bike as very busy at the moment. However, I had a concern after reading a recent post where others members talked of how hard there bikes were to kick over. Mine is quite easy, yet it has a new rebore and new genuine Honda piston and rings. ...