How to change a Clutch on a 1979 Honda XL500S (1980, 1981, 1982, 1983, XR500)

[@abridgedmammal0973]

Hey there need some help with my xr350. The clutch arm won’t engage the clutch.

[@Roolis77]

Hello , Sir, one more question . I am not sure, but I think I am missing clutch push rod .On your video 1:14 when You open the right cover I see it still in cover like small "hat" which should push bearing on the clutch basket. Is there something else in between? I have that "hat". But when I look at engine diagram part OEM number 22847428000 is different from that "hat" . Am I missing something ? Please advise

[@WeekendHobbyMechanic]

Maybe but this one didn't have it. Still works fine. I know my 1982 XL500 has a different style. Has a pin inside the bearing with a different pusher.

[@Roolis77]

@@WeekendHobbyMechanic thank you

[@michaelgarcia5102]

Need some help please, what is going on here? When I removed the clutch assembly everything lined up. When I replaced the clutch discs and put it back on to engine I torqued the retaining nut to 33 ft lbs. When I tried to put the lifter plate back on none of the bolts that hold it down are lining up. I have check everything several times. What I'm I doing wrong. After I loosen the retaining nut the I was able to line up the bolts. ????????. 🤔🤔🤔🤔🤔

[@WeekendHobbyMechanic]

Do you mean the bolts on the side engine cover? Are you pulling back the decompression lever? @6:22 in video.

[@Roolis77]

Hello, thanks for Your videos . It really helps me . I have one question - minute 1:17 where you explain about the washer when you have it on cover and that cover place from inside there is a pin . What is a purpose of that pin? because mine is broken off the whole corner together with pin. and I am thinking whether to weld it back aluminium and install it or not?

[@WeekendHobbyMechanic]

The guide pin is to centre the side cover into position. It’s not under heavy load so I’d just install the cover without it.

[@Roolis77]

@@WeekendHobbyMechanic Thank You so much.

[@Roolis77]

seems I found answer while watching your video :) so I am covered I have that "hat" so all ok . Thanks For Your videos !!!!!!!!!!!

[@samuelburnham6655]

Sir from what research i have done only the 250 has that style engaged the 500 s all take the pin that goes into the counter shaft

[@WeekendHobbyMechanic]

👍

[@warpedsunshine1964]

How do you adjust the clutch cable. I have an 81 xl250s it looks the same internally.

[@WeekendHobbyMechanic]

The cable is held by a bracket near the side cover of the motor. Loosen the two nuts and adjust the cable length.

[@smth761]

Hey, I just changed my clutch too, but now the clutch lever has little to absolute no tension and it doesnt disconnect the motor from the gearbox when pulled anymore. Any thoughts on what I did wrong?

[@WeekendHobbyMechanic]

Have to pull the cover off. Something is not right. Watch my video @5:50mins.

[@kennethhicks6755]

Hey brother.. can I ask where you got the new clutch hardware..I have an 80 and it don't have much clutch left

[@WeekendHobbyMechanic]

Local motorcycle shop, parts department. (Aftermarket)

[@kennethhicks6755]

@@WeekendHobbyMechanic is there maybe a specific size.. or something to look for.. or did they just look it up for you.

[@WeekendHobbyMechanic]

@@kennethhicks6755 They looked it up for me.

[@danielbremner4142]

My ‘78 has a peg inside that bearing.

[@hendriklottering4768]

Hi I'm looking for a xl 500 engine can you help me

[@WeekendHobbyMechanic]

Try Facebook XL500 group.

[@hendriklottering4768]

Sorry xr500 engine for Honda xl 250 I have see you video of the xl250 & xr500

[@bradleymadosh911]

How fast are those bikes

[@WeekendHobbyMechanic]

Xl500s 95mph, XR500 has a bigger rear sprocket 85mph.