Changing the kick start shaft, for a 1982 honda XL500.
Hi, just wondering how i split the motor of my XL500, i have it off the bike, with the clutch removed and both side coverings removed. where do i go from here?? i did buy a manual, just awaiting delivery. (but i'm too keen to get it done!)
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Not a very clear question so I will try to help... It sounds like you replaced your piston and rings. Now if I understand the engine will not kick over because the kick start lever is stuck at the top position OR it is stuck in the bottom of the kick? If at the top;
Remove the spark plug so you will not have to deal with the compression confusing the issue.
First, with bike in neutral does the engine turn over easily when you put a socket onto the bolt at the end of the crank shaft?
If the crankshaft turns over easily then there is a problem in the transmission. If not then;
- Your piston is stuck because it is to big or rings were not installed correctly. Ring gap may be an issue, or you may not have used assembly lube on the wrist pin etc. etc. If the engine does not spin easily R&R the piston. There can also be something like a socket or old part that fell into the crankcase at some point.
I suppose that the clutches may be sticking to the pressure plates if the bike was apart for a period of time too. R&R the clutch pack to inspect. Before you remove the clutch pack it may be a reasonable idea to loosen the bolts that apply pressure to the clutch springs to see if that loosens the plates.
If you do remove the clutch pack make sure the bike is in neutral so you can grab the output shaft and spin it by hand. It should be easy to spin the transmission once the clutch is removed. Since you would need to R&R the clutch to split the case it is a good idea to check that it is not a problem in the transmission.
If it does turn easily then put the bike on a center stand so the rear wheel is off the ground. Put it in first gear and try again... If the crankshaft will not spin via end bolt then something is in the bottom end or transmission.
If the engine spins via crankshaft end bolt then the kick start lever has a problem and splitting the crankcase is the next step. Comment below with any new info and I will try to get back to you.
You may want to get a service manual to work on this one. The expanded parts diagrams that are available for ordering parts online will show you all the parts. If you can not find some picture of the 100cc models the 1974 CB125 is basically the same. The design of your motor dictates that you will have to take the engine out of the frame, pull the top end off, and split the cases to get in to the area that houses the mechanism you want to replace. You may be able to pull good used parts out of a salvage motor locally or even purchase a used motor or donor bike if the price is right. You will need a complete gasket set for the motor. As for the change in the kick shaft size, it may be that the shaft was replaced before with a shaft from the CB125. You may have to measure your shaft and then measure the shaft on the motor you are taking the replacement part out of. Chances are you need to replace several parts to repair the kick mechanism. You will have to disassemble the motor to find out everything you need to properly fix your classic.
I dont know exactly 100% what the problem is but i highly recommend changing all fluids on the bike and for the kickstarter there is something wrong with the kick starter shaft. If you dont know much about bikes i would probably take it into a shop to get looked at.
Hi, you might find the nut holding the clutch basket onto the shaft has come loose, so instead of pulling the clutch plates apart you are just pulling the clutch basket along the shaft.
or if the bike has sat for a while you might find the clutch plates have stuck together, this isn't that rare, you can start the bike and roll it along at about 1st gear speed,
then click it into gear,
then pull the clutch in and rev the engine, this should make the plates loose again.
hope this helps, please rate, thanks, good luck
if the bike is a shaft drive,then the oil you are referring to is a gear oil only,will be fine in the rear drive unit as most standard hondas use 80-90 as standard....but under no circumstances put this grade of oil into your engine or gearbox,you will destroy the motor in a very short time
Change the oil and oil filter. Ride the bike for 50 miles or so then change th oil again but w/o another filter. Dirt and grit in the oil is making the clutch grab and not fully disengage. Changing oil will flush the gearbox. 10w40 motor oil.