Author Topic: 76 XS500 engine stuck after adjusting valves  (Read 238 times)

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Offline rumorhazard

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76 XS500 engine stuck after adjusting valves
« on: July 02, 2018, 11:42:52 PM »
So, I have this cafe conversion XS500 that was shooting flames on deceleration. Pretty sure that the problem wasn't coming from the carbs, and realized that I had never set the valve clearance. I went to adjust the valves, but one thing happened as I was doing that.

In the FSM it says to turn the crankshaft clockwise, which I thought was a little bit odd because on the Hondas I have it's always turned counter-clockwise. Whatever, no big deal, I grab the 10mm allen key and set about to turn it clockwise, but it is insanely tight. It budges a little bit but the timing plate didn't move. I figure I don't want to force anything so I adjusted the valves by getting to TDC with the starter motor and the kickstarter. The kickstarter became too difficult to move (with the sparklpugs out) so I just used the starter.

The valves were in a big need of adjustment so I put everything back together and tried to start it. It turned over a little bit but then the motor got stuck. The kickstart is totally froze, and the starter just clicks. It started up and ran just fine before hand.

I think it's changing gears and I can get into neutral, but that motor will just not move. I've tried putting it into a higher gear and turning the rear wheel, but that doesn't make a difference.

Is it possible that I was supposed to turn the crankshaft counter-clockwise, ended up loosening it, and now face a whole rebuild? I specifically checked the FSM and it says clockwise!!

Or, has the clutch just suddenly died on me?

Not sure how to proceed on this one.

Offline mvluv13

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Re: 76 XS500 engine stuck after adjusting valves
« Reply #1 on: July 03, 2018, 10:34:07 AM »
Sounds like you have jumped one or two teeth on the cam chain. Only way to properly check is take valve cover off, check piston height and see if it is sitting against a valve open on the cam love. Don't ask how I know. Mine did it twice before I put a later model tensioner on.
Good luck with it.

Offline CrouchyUK

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Re: 76 XS500 engine stuck after adjusting valves
« Reply #2 on: July 04, 2018, 09:05:31 AM »
Back to you originally not being able to turn the engine with the 10mm hex- you were removing the plug first and inserting the key inside the casing hole to engage the actual caphead on the end of the crankshaft?  Just trying to think of a reason why the starter could turn the engine, but you could not.....
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline CrouchyUK

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Re: 76 XS500 engine stuck after adjusting valves
« Reply #3 on: July 04, 2018, 09:07:44 AM »
Oh- clockwise only is correct- apart from taking up all the various backlashes for setting, this actually tightens the caphead on the end of the crank.  It has a lock tab, but turning it CCW could loosen it....
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2