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Author Topic: Am I the Pontius Pilate of this CX500?  (Read 6188 times)

Offline Odontologist

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Re: Am I the Pontius Pilate of this CX500?
« Reply #90 on: Feb 13, 2018, 03:44:06 »
Although I'm not doing this build on a tight budget, I do love some of the simple and effective solutions that recycle parts......such as the solution to seal the tacho cable mount since I won't be using a mechanical tacho. I WAS going to buy a plug, but this is a gem. It was suggested by Sidecar Bob from the CX500 forum. It goes like this:

"I cut the cast end off of the old cable, cleaned the cut end up and ran a 1/4" tap into the hole, then screwed a bolt into the piece and installed it the same way the cable would go."

Only difference is that I don't have SAE taps, so I broadened hole to 5.5mm and tapped a 6mm thread.

The metal is quite soft and the tap clogged up easily. It polishes up nicely. I'm guessing a high zinc content alloy.....but don't really know.
Again, a simple quick job that put a big smile on my face.








Ahh yes. I also cut the end of the camshaft. Mechanical cam driven fan out....electric temp sender operated fan in.
Run out of zip ties? Dental floss is an excellent alternative.

1982 Honda CX500 Roadster build

Offline crazypj

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  • Split personality, I fake being smart
Re: Am I the Pontius Pilate of this CX500?
« Reply #91 on: Feb 14, 2018, 20:09:58 »

The seat support has some bolt mounts 65mm apart...I believe for the rectifier/regulator. However, the mount holes on under side of the stock reg/rect are 68mm apart.





Quick tip, when measuring hole 'center' go from edge to edge.(move rule 5mm to 'right') If holes are same diameter it's exact size. If holes are different diameters you either add or subtract half the difference depending on which 'edges' you measured from)
« Last Edit: Feb 14, 2018, 20:13:00 by crazypj »
'you can take my word for it or argue until you find out I'm right'
Best thing I ever overheard
"yep, PJ's my boss, he taught me everything I know, just didn't teach me everything he knows"
Brian Morgan, 1982

CB360's,  http://www.dotheton.com/forum/index.php?topic=11736.0
XS650,  http://www.dotheton.com/forum/index.php?topic=11922.0

Offline Odontologist

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Re: Am I the Pontius Pilate of this CX500?
« Reply #92 on: May 14, 2018, 07:09:37 »
Been a while.
Frame and bits back from powder coaters. Time to continue. To get me in the mood, I started by putting the odd bits and pieces left on the engine.
Last week, I was short one spring and washer for the oil bolt. Thanks to CXPHREAK from the CX500forum....and SHAZZAM! One spring and washer magically appeared.
Ahhhh.....the wonders of the internet, when combined with traditional postal services....what a wonderful world.



Thanks CXPHREAK!

New bolt O ring...



New filter and housing O ring seal.



Housing on...but.....forgot to polish the bolt head.



Couldn't leave it like that.
That's better.



Nice little job to put me in the mood.
Run out of zip ties? Dental floss is an excellent alternative.

1982 Honda CX500 Roadster build

Offline Odontologist

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Re: Am I the Pontius Pilate of this CX500?
« Reply #93 on: May 15, 2018, 05:34:55 »
It's time to start putting things back on the bike, but there's still several things to be done on the way.

The rear break overhaul. Pulled it apart, cleaned everything in de-greaser, prepped the cover with some 360 grit, primed and 3 coats of VHT Caliper paint.







New EBC shoes and springs to go in.

Then the swing arm. I removed the bearings before sending to powder coaters. Time to put them back on.
I'm a little psychic (not psycho) and I can tell that some amongst you are seeing problems for me up ahead.
Let's find out.

First, refit a new dust plate in the left side bearing housing. No problems so far.



Correct bearings in hand. Still good.



Driving outer bearing race...first attempt. No good.



Heat up the swing arm housing. Second attempt. No good.



Freeze outer race. Third attempt. No good.



The photo above shows an unfortunate event about to happen. It did. This is not a staged photo. I'm video taping for my youtube video series, and I take the photos out of frames from the video. There's just no need to see what happens next.

Finally, animal instinct....just bang harder. Oops.



That's the powder coat cracking off. As it turns out, it's pretty thick.



Sooooooooo........I thought I had been pretty clever by placing bolts and nuts on all threaded mounts to stop powder coat from obstructing threads, etc, but it seems I forgot about the bearing housings. Well, not so much I forgot, but didn't see it coming.

Anyway, I used my laboratory motor (dremel style) to removed the coat from inside the housing, left a good solid edge on the powder coat so it wouldn't continue chipping off, placed the outer race....easily, blocked it out, and primed and touched up with some metallic silver paint from a can. Don't look too bad.





What I will say about this episode, is that although I have placed bearings in the engine so far, I didn't know how thick paint or powdercoat is, and did not have a preconceived idea of how much force was required to press these bearings in. The more you do...the more you learn.

The right side bearing didn't present such a challenge.

Using a bearing puller to knock out the old outer race.





New outer race went in without dramas.



But fitting the housing in the frame may present some yet. I think I will be back using my dremel again....but will leave it for another time.

Run out of zip ties? Dental floss is an excellent alternative.

1982 Honda CX500 Roadster build

Offline crazypj

  • Posts: 12887
  • Split personality, I fake being smart
Re: Am I the Pontius Pilate of this CX500?
« Reply #94 on: May 15, 2018, 13:47:01 »
People forget about bearing housings and shock mounting studs all the time, even when 'ordinary' paint is used
If you have pictures of frame before stripping you'll probably see Honda masked off a few area's, including a ground point (usually square as they just stuck some tape over a bolt hole)
'you can take my word for it or argue until you find out I'm right'
Best thing I ever overheard
"yep, PJ's my boss, he taught me everything I know, just didn't teach me everything he knows"
Brian Morgan, 1982

CB360's,  http://www.dotheton.com/forum/index.php?topic=11736.0
XS650,  http://www.dotheton.com/forum/index.php?topic=11922.0

Offline Odontologist

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  • Umina Beach, Australia....Where does that part go?
Re: Am I the Pontius Pilate of this CX500?
« Reply #95 on: May 16, 2018, 04:37:40 »
Live and learn crazy.

A lot of stuff had been getting in the way, but  I managed to replace the rear brake shoes (EBC) and springs, polished a few bits, and put the thing back together.





I also managed to work on the recycled rear hub, which gets new bearings....retainer side first into greased up space.



+ the retainer. Punched to prevent loosening



On the final drive side the distance spacer goes in and then the bearing in well greased bearing hub.





O ring



Plenty of grease on the O ring and on the flange splines.



....and replace bolts to specified torque.

Run out of zip ties? Dental floss is an excellent alternative.

1982 Honda CX500 Roadster build

Offline cxman

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Re: Am I the Pontius Pilate of this CX500?
« Reply #96 on: May 16, 2018, 07:50:32 »
i hope you put some loctite on those flange  bolts
1978 CX650 Super Deluxe
1979 XS1100 Special
1974 xl350
1983 cx650 Custom
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1974 kawasaki 350 bighorn
1983 GL1100 aspy full dress
1983 GL1100 Nekid
and a bunch of others

Offline Odontologist

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  • Posts: 69
  • Umina Beach, Australia....Where does that part go?
Re: Am I the Pontius Pilate of this CX500?
« Reply #97 on: May 16, 2018, 08:09:43 »
No. FSM doesn't  mention it....but I can still do that...and I will. Thanks cxman.
Run out of zip ties? Dental floss is an excellent alternative.

1982 Honda CX500 Roadster build

Offline cxman

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Re: Am I the Pontius Pilate of this CX500?
« Reply #98 on: May 16, 2018, 11:17:44 »
factory puts the white tough stuff on them

i use blue and have no problems

none and you will sooner or later
1978 CX650 Super Deluxe
1979 XS1100 Special
1974 xl350
1983 cx650 Custom
1973 cb750
1980 cb750
1981 cb650
1982 cb900 c
1974 kawasaki 350 bighorn
1983 GL1100 aspy full dress
1983 GL1100 Nekid
and a bunch of others

Offline crazypj

  • Posts: 12887
  • Split personality, I fake being smart
Re: Am I the Pontius Pilate of this CX500?
« Reply #99 on: May 16, 2018, 12:34:47 »
Is the bearing retainer ring all the way down? It looks like there's a gap in picture?
'you can take my word for it or argue until you find out I'm right'
Best thing I ever overheard
"yep, PJ's my boss, he taught me everything I know, just didn't teach me everything he knows"
Brian Morgan, 1982

CB360's,  http://www.dotheton.com/forum/index.php?topic=11736.0
XS650,  http://www.dotheton.com/forum/index.php?topic=11922.0