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Old 09-04-2012, 03:26 PM   #1171
Magestyk
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Joined: Aug 2006
Location: Planet Earth
Oddometer: 348
Quote:
Originally Posted by skorpioskorpio View Post
Where are you looking for parts? A surprising number of cables and rubber parts are still available from Honda, and there is also:

http://hondarestoration.com

for harder to find parts.
Good website. Never came across that one.
I was looking at these...
http://www.motosport.com
http://www.bikebandit.com
http://www.dealercostparts.com

But I think I'm gonna go MacGyver on this, and go a different route because most parts are either hard to find or too expensive.
Would my bike/engine run on a 1996 XR250L Wiring Harness/CDI/Regulator?
It's less expensive, easier, and simple.
http://www.dealercostparts.com/pages...V6MKV64F2800AC

There are two key components that I need to wire this up. The CDI, and Rectifier/Regulator.

I'm guessing aftermarket would be way easier to find.
Wonder if this CDI would work to help get the bike going.
http://www.motorcityreman.com/hondaxr250cdi.html
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Old 09-04-2012, 11:43 PM   #1172
skorpioskorpio
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Location: los Angeles, CA
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Pretty sure your bike is 6V and pretty sure a 1996 is 12V.
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Old 09-17-2012, 10:23 AM   #1173
STARSKEY
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Location: Clinton, UT
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Ugh!

First good, long day of riding the XL500S and the turn signals stopped working. Could it be something as simple as the fuse? Of course not! Guess it's time to start taking things apart and begin wishing I had a wiring diagram.
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STARSKEY screwed with this post 09-17-2012 at 10:24 AM Reason: mah spalling sukz
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Old 09-20-2012, 05:36 PM   #1174
Yokomo
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Location: The Little Apple
Oddometer: 2,192
My old Honda I had.

http://www.youtube.com/watch?v=vh_VYnRkEI0

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Old 09-21-2012, 11:38 AM   #1175
foxtrapper
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Quote:
Originally Posted by STARSKEY View Post
First good, long day of riding the XL500S and the turn signals stopped working. Could it be something as simple as the fuse? Of course not! Guess it's time to start taking things apart and begin wishing I had a wiring diagram.
Ask and ye shall receive.
http://zorch.maow.myip.org/bikes/wir..._1979-1981.jpg
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Old 09-23-2012, 01:28 PM   #1176
STARSKEY
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Originally Posted by foxtrapper View Post

I cannot begin to describe your level of awesomeness. With wiring diagram in hand, I gallpod to the grarage and began starting from "the beginning". I start the bike and make sure the signals didn't "heal" themselves, which they haven't.

Yes, fuse is good, but I'm not getting voltage out of the fuse......because their is no voltage going into the fuse! Battery appears okay (it was replaced just before I got the bike) but I pull it out (must need charging, right?). Well lookie there. The back cell (the one you can't see when it's in the bike) is low on fluid. Top it off with a little water. Throw the battery back in the bike and finagle my battery charger on it. Yup, sucking a load. I try the signals, and realize that they are trying to work but the indicator isn't working. I pull it out and swap it with one of the odometer light bulbs, and try it again.

TADAAAA!

Pull charger, bolt it back together, start it, and blinkey blinkey life is good!
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Old 09-29-2012, 09:52 PM   #1177
dorkpunch OP
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Location: Blackfoot, ID
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Drug out my last remaining XL from storage this afternoon... Poor old gurl was covered in dust in spite of being covered by a tarp in the shed.



Gave her a quick spit shine, looks lots better. Even got it to start after about 10 kicks- which is pretty good, all things considered.





Love this view of it.



Its a boooger to start, may have something to do with the Venolia 12:1 piston, longer duration cam, and stupid big (and STILL not dialed in right) Mikuni.



Custom cherry bomb exhaust. Sounds good. Nice rumble, and surprisingly not that loud unless you really get on it.



Need to use this bike more. Don't know what my problem is, I get it out just in time for it to need to go back into storage for winter?!
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Old 09-30-2012, 07:08 AM   #1178
OldJohn
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Location: North of Portland, Oregon but south of Seattle
Oddometer: 10
That's awesome, I like it!


Somebody just posted one in my area for sale....hmmmm....
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Old 09-30-2012, 07:23 AM   #1179
jitterymonkey
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Location: Canton Ohio
Oddometer: 406
Cool looking XL.
I hope none of your body parts were used to make that dent
in the tank.
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Old 09-30-2012, 12:12 PM   #1180
redprimo
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That sounds like the same engine mods that someone did to my xl500s, unfortunately the Venolio piston was toast so I droped in a 10:1 Wiseco.

Whats on the end of that crankcase vent tube and where does it go?
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Old 10-01-2012, 10:16 PM   #1181
rodgerdodger
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I've got a problem stripping the front forks. I've drained the fork lower and am taking out the inner spring. The allen key at the bottom of the fork is loose, though the bolt simply keeps turning with the inner spring inside the fork leg, i.e. no matter how many times I turn it, it keeps rotating though won't come out.

Has anyone had this problem before? Any suggestions on how to get it out?

Cheers.




rodgerdodger screwed with this post 10-02-2012 at 03:56 AM
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Old 10-02-2012, 12:44 AM   #1182
skorpioskorpio
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Location: los Angeles, CA
Oddometer: 405
Quote:
Originally Posted by rodgerdodger View Post
I've got a problem stripping the front forks. I've drained the fork lower and am taking out the inner spring. The allen key at the bottom of the fork is loose, though the bolt simply keeps turning with the inner spring inside the fork leg, i.e. no matter how many times I turn it it keep rotating though won't come out.

Has anyone had this problem before? Any suggestions on how to get it out?

Cheers.



If it's like the earlier forks the top of the damper (which is the part that is turning) looks like from the top like a tube with a bar across it ( Crude character drawing: (--) ). To undo one of my stubborn ones I used 2 hanger bars from a vertical file which happen to be about the right size to wedge into the 2 half moon openings, basically about 1/8" by about 3/8" bar stock about 2 feet long.
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Old 10-02-2012, 03:59 PM   #1183
pvangel
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Location: South Salem, NY
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Quote:
Originally Posted by rodgerdodger View Post
I've got a problem stripping the front forks. I've drained the fork lower and am taking out the inner spring. The allen key at the bottom of the fork is loose, though the bolt simply keeps turning with the inner spring inside the fork leg, i.e. no matter how many times I turn it, it keeps rotating though won't come out.

Has anyone had this problem before? Any suggestions on how to get it out?

Cheers.




Just put the spring back in and hand tighten the cap and then use an air impact gun while holding the fork upside down and push down a bit, should come right off.
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Old 10-02-2012, 04:00 PM   #1184
pvangel
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like this.

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Old 10-03-2012, 10:07 PM   #1185
Canadian80
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Hi all,

I'm in the process of doing a complete restore on an 81 XL250S, and while I'm at it, I would like to know the exact differences between the 81 and the 78 models? In particular, I'm concerned with the side panels and how they mount - and any other differences in that area.
I prefer the look of the 78 model with the smaller side panels and different tank decals, so I was thinking if it's not too big of difference, I might convert it all to 78 decals/sidepanels.
Are there any other physical differences in the frame or anywhere else?

Thanks in advance,

-Ryan
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