Just Bought an XL500

[Jargle]

Hi Mark, I just an XL 500 recently also...mine has that little oil leak, which I gather is quite common. I'd be interested to learn what you do to fix it, I'll have a go if it's not too tricky. Pic attached.

cheers

[M6NTL]

Hi Mark, I just an XL 500 recently also...mine has that little oil leak, which I gather is quite common. I'd be interested to learn what you do to fix it, I'll have a go if it's not too tricky. Pic attached.

cheers

Hi, it's not a particularly hard job as long as nothing breaks or threads strip as you are doing it. The rocker cover has to come off, which is best done with the engine out of the frame (a dead easy job) as there isn't enough clearance above the engine when it's still in the frame. You CAN do it by dropping the engine a couple of inches, but you might as well just take it out.
When the rocker cover is off there are some o-rings that'll need replacing, and a gasket too (I believe). Use three- bond gasket goo and you'll be rocking.
A good time to check the camshaft journals while you're in there.
Like I say, easy if things don't break, and threads don't strip when you put it back together!!!
Cheers, Mark.

[Jargle]

OK cool, I'll rope in my mate who is way more handy than me and have a go. Are you going to do any trails, or just stay on road? I just joined the TRF to do green lanes.

[M6NTL]

I will indeed be doing some green lane riding. I have a bike for the road (a rather highly performance modified Kawasaki 750 Turbo with GSX-R forks, brakes, swingarm, one-off WP rear shock etc etc).
The primary reason for buying this XL was that my son is about to turn 17 and I bought him a Yamaha TDR 125. I want to ride with him to attempt to instill some road craft before he's out on the road alone...
What's the TRF?

[Neilios]

Trail Riders Fellowship, google it for your local branch.

Good look with the XL I love mine.

[M6NTL]

Trail Riders Fellowship, google it for your local branch.

Good look with the XL I love mine.

I will, thank you!!!

[M6NTL]

Well, I've started on my oil leak fix.
Here's the bike on my drive this afternoon at about 3pm...



I took the gaiters off the forks to check if they were pitted - they aren't bad at all.
Although non-standard, I'm VERY chuffed that someone has fitted a 21" disc brake front end!!!


And here's the engine in the garage about 45 minutes later (sorry about the crap iPhone photo)...




It looks like some of the bolts holding the rocker cover on are loose, and some have nuts spun onto them. I'm rather dreading taking it off in case the threads are screwed... (pardon the pun)...
Certainly it's been bodged before, there's sealant goo all around the join, and some nob has painted the engine over this...

I had a reply back from Honda about extra details for the bike - the cheeky buggers said they can tell me where it was made and where sold for £28..!!..
F*** that, I'll stay in the dark..!!..

[catteeclan]

And here's the engine in the garage about 45 minutes later (sorry about the crap iPhone photo)...




It looks like some of the bolts holding the rocker cover on are loose, and some have nuts spun onto them. I'm rather dreading taking it off in case the threads are screwed... (pardon the pun)...
Certainly it's been bodged before, there's sealant goo all around the join, and some nob has painted the engine over this...

Loosing threads in the top is all part of the fun on these engines. Don't think the alloys to clever.

[M6NTL]

Bloody Bodging Previous Bloody Owners...
So, lots of crap helicoils and some timerserts (not) holding the cover on properly and (not) keeping all the oil inside where it should be. Some work to do there methinks...

However, my major concern is the camshaft - it doesn't look good to me...

What do you think I should do? Run it as is, or try to get a better cam???











The endfloat is approx 0.15mm.
Any opinions appreciated!!!

Cheers, mark.

[catteeclan]

When the threads get pulled out, not alway by over tightening, what other option of repair is there? Top of mine is full of Vcoils. The biggest pisser is when you do one, put it together and another thread goes.

Cam looks ok from the pics, could turn the engine to get a better look.