Motorcycle Electronic Ignition Troubleshooting Honda XL500R

Get the latest Flash Player to see this video.

* HD format might not be available

Play in: Low Quality | High Quality | HD Quality *

Local Comments (0)

Nothing Found!

Youtube Comments (29)

Apr 6, 2012
hoohoohoblin Says:
The guy who sold me the bike put the 79 XR500 motor in the 82 XL500, so I don't know exactly what he did to make it work, but the electronics outside of the motor are all 1982. I think the alternator is a stock 79 unit, and it works with the newer electrics. I can't be 100 percent sure though. He may have switched alternators.

Apr 6, 2012
GravvyTrain Says:
I am about to put in an '80 xr500 motor to my xl500r. Do you need to switch out the generator/rotor assembly to the 12v for everything to work right? It looks like the generator wire on the XR motor is different.. thanks hoblin

Apr 6, 2012
GravvyTrain Says:
I came across this hbhonda.com site they have almost everything stock brand new from california..

Jan 23, 2012
hoohoohoblin Says:
You're right. The guy who sold it to me said it was a 78 motor. I guess he was off by a year. I also bought some extra electrical parts to use as spares. You can't get new ones anymore.

Jan 23, 2012
SeriousSchitt Says:
Thanks for posting this educational video, I just purchased a spare "pulse pick-up" the other day as part of my electrical arsenal, just in case I ever need one. By the way, I thought that the Honda XR 500 debut in 1979, not '78 (1979 Honda XR 500Z!!)

Dec 26, 2011
hoohoohoblin Says:
@bmwfan4lyfe Looking at the wiring diagram for the 1982 bike, the wires to the CDI box are as follows: Black & White goes to the engine stop switch. Red & Black goes to the alternator. Dark Green goes to the negative battery terminal. Green & White goes to the pickup coil. Blue & Yellow goes to the other wire on the pickup coil. Yellow & Black goes to the ignition coil.

Dec 25, 2011
hoohoohoblin Says:
@bmwfan4lyfe You would need to replace the CDI, Coil and wires to get it working. On an old bike with mechanical ignition points, you could rewire it yourself and get it working, but on a modern bike with electronic ignition you need all of the electronic ignition parts to get it working. Sometimes you can find them all really cheap on eBay, including a new wiring harness.

Dec 25, 2011
guz04087 Says:
hello i have an 82 xl 500r too, my problem with it is i kick and kick it and it wont start for a long time. sometimes i have to get a couple of friends to help me push start it after it warm its easier to satrt but still requires effort to get going any ideas?

Nov 30, 2011
hoohoohoblin Says:
It's a very frustrating problem, but you sure feel good when you finally replace the right part. It took me a while to get it figured on on the Honda, but now it runs great.

Nov 30, 2011
MOUSEBOWEN Says:
my 1971 suzuki ts250 used to do the same.stars rihjt up and 15 minutes later dead.so so and replace many parts electrico..anyways the problem was a stator generator.bummm fix the problem running like champ

Oct 31, 2011
hoohoohoblin Says:
Yikes!

Oct 31, 2011
poo12318 Says:
u got it easy i have a used atv and when i got it the cdi box was melted to the mufler

Jul 2, 2011
hoohoohoblin Says:
Thanks. I'll never know for sure what was wrong, but it's running great now and I've gone hundreds of miles since I shot the video. When in doubt, replace everything.

Jul 2, 2011
pinoy968 Says:
hello Sir, your right change the ignition coil, it seems to me the ignition coil is the problem i had that problem before. i wish i can help you some of your problems thank you.

Apr 10, 2011
gordonemoore Says:
I do most of my work these days on old bikes. Thank goodness for used parts!

Apr 9, 2011
hoohoohoblin Says:
Good advice. Honda stopped making new parts, so I had to go with used, and everyone selling used parts on eBay says it came from a good running bike (If it was running so well, why did they take it apart?) but sometimes the parts are bad. I figured if I replaced everything it should fix the problem. I rode the bike 10 miles today with no problem, so I think it worked.

Apr 9, 2011
gordonemoore Says:
The best test is substitution of a known good part. Easy in a shop, the mechanics don't have to pay for them first. Another way to test suspected heat-affected parts is by cooling them rapidly with freon or a fire extinguisher or even cold water (use yer head!).If it starts, you found it. If the part has the word 'coil' in it, it's usually a broken wire that expands with heat and goes open circuit and makes contact again when it cools. In 'black boxes' it's usually a component gone bad.

Apr 9, 2011
Redrider43 Says:
ya the air cleaner mite be yr problem cause it catches all the crap befor it goes into the engin it mite be cloged full of crap so u mite have to get a new air cleaner

Apr 9, 2011
hoohoohoblin Says:
Thanks. Oil is good. Haven't looked at the air cleaner in a while. I'm on my 3rd CDI box. It runs great now, but I still need to take it on a long trip and see if it tries to kill me again.

Apr 8, 2011
Redrider43 Says:
i would: A. check and or change the oil B. check air cleaner C. get a new cdi box

Apr 7, 2011
hoohoohoblin Says:
Thanks. I wanted to show people the basic parts involved in the ignition process so they can figure out what may be wrong with their bike. I think I got it fixed. One of these nights I'm going to ride laps around my neighborhood for 20 miles to see how it does. I really like the how-to videos you've been doing. Keep it up.

Apr 7, 2011
DarkFlightVlogs Says:
I love the technical jargon.....nice video. Hope it works out now for you and you get more than 7 miles ;)

Apr 7, 2011
hoohoohoblin Says:
The Honda XL500R doesn't have a sidestand switch. I replaced the pickup coil when I first had the problem and it didn't help. Then I replaced the CDI box and it worked fine for a long time, but then it started happening again. This time I hope I fixed it. I replaced the CDI box, coil, and regulator/rectifier. That should cover it.

Apr 7, 2011
hoohoohoblin Says:
I don't know yet. I rode it a mile to the gas station to fill it up and back. It started and ran fine. When the engine died before, I was doing 75 mph on the freeway in the rain. Now that I'm testing it, I want to do it in the daytime in light traffic so I don't get hurt if it dies. I thought about riding it to work today but didn't.

Apr 7, 2011
MCTeck Says:
My 1987 Yamaha XT 600 had the same problem. Every thing pointed to the cdi. Changed it, {$150} Did not fix the problem . It turned out to be the pickup coil. Also check your charging voltage.[at battery] My friend bought a 2000 Aprilia Pegaso[ single cyl] It would run, turn off , re-start ,would cuttout, Restart ok... cuttout.on and on. Turned out the voltage reg. failed .20 volts going to the cdi Fried the cdi! Also my Xt's side stand switch failed. Does your Honda have one?

Video Details

My Honda XL500R motorcycle would stall after going 7 miles. If I let it cool off for half an hour or more, it would start and run fine for another 7 miles. I replaced the CDI box and it was better for about a year, but then it happened again. This time I replaced all of the electronic ignition... More