DO THE TON

Blood Sweat Tears and Grease => Projects => Cafe Racers => Topic started by: Odontologist on Nov 07, 2017, 04:17:57

Title: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 07, 2017, 04:17:57
Greetings.
I'm a recent member, and this is my first post.
I have ridden bikes since age 17 and now I'm in my 50's and still riding.
I have never done anything to a bike, nor do I know anything about how they work.
I do however know how to read a manual.

I have had an itch to build a cafe racer for some time, and no amount of Sorbolene cream would satisfy.
I found a very decent 1982 Honda CX500 Shadow (Australian model), and set about the task of satisfying my itch.

I feel that this project will either end up something wonderful....or a total disaster.
If you come on the journey, you will find out.

I have torn down the bike and engine, although there was really nothing wrong with it.....but I was set out to learn....and I was told on another forum that unless I do things for myself, I'm a worthless turd (not exact words, but that's how I understood it).

Below are some photos of where I'm up to, and a link to more complete youtube videos if you like detail. I will add to the log as I go along, probably once a week as I keep working on it.

I welcome questions, although I need less of those than answers, and I am not thin skinned, so throw all your shit at me if you must!
But do it with a smile.
Thanks
Mario

1982 CX500 Shadow before the slaughter.
(http://www.dotheton.com/gallery/111030-061117215708.jpeg)
https://youtu.be/mvYAOsI3p5w (https://youtu.be/mvYAOsI3p5w)

HAD A BIT OF TROUBLE REMOVING PIPES
(http://www.dotheton.com/gallery/111030-061117215833.jpeg)
STRIPDOWN PROCEEDS WITHOUT INCIDENTS
(http://www.dotheton.com/gallery/111030-061117220157.jpeg)
https://youtu.be/hY3JW4_eSXY (https://youtu.be/hY3JW4_eSXY)

Haaaaaghhhh!....THE WIRING
(http://www.dotheton.com/gallery/111030-061117220457.jpeg)
https://youtu.be/j20pW3PNr_U (https://youtu.be/j20pW3PNr_U)

GETTING THAT AIR BOX OUT WAS A LITTLE TRICKY.....OR IS IT ME?
(http://www.dotheton.com/gallery/111030-061117220627.jpeg)
THE LITTLE ENGINE.....WHAT DO I DO WITH IT NOW?
(http://www.dotheton.com/gallery/111030-061117220742.jpeg)
https://youtu.be/WJWFanjFYFg (https://youtu.be/WJWFanjFYFg)

WHAT IF I PULL IT APART.....EVEN THOUGH THERE'S NOTHING WRONG WITH IT?
(http://www.dotheton.com/gallery/111030-061117220847.jpeg)
https://youtu.be/324sicX1c40 (https://youtu.be/324sicX1c40)

COULDN'T RESIST THIS PICTURE. IT'S A GREEn STRAIGHT OUT OF SCIENCE FICTION.
(http://www.dotheton.com/gallery/111030-061117221050.jpeg)
https://youtu.be/K5GId7VOX4g (https://youtu.be/K5GId7VOX4g)

OIL PUMP AND TRANSMISSION. GETTING IN WAY OUT OF MY DEPTH.
(http://www.dotheton.com/gallery/111030-061117221221.jpeg)
https://youtu.be/UTNRmj39R0M (https://youtu.be/UTNRmj39R0M)


This is as far as I got with the videos. They take much longer to put together working on the bike.

THE MUCH TALKED ABOUT WATER IMPELLER. THIS ONE LOOKS IN PRETTY GOOD NICK.
(http://www.dotheton.com/gallery/111030-061117221330.jpeg)

ROTOR OUT AND LOOKING STRAIGHT DOWN THE CAM MECHANISM BARREL. VERY NERVOUS AT THIS POINT.
(http://www.dotheton.com/gallery/111030-061117221506.jpeg)


THAT'S THE TRANSMISSION IN MY HANDS. I THINK I'M HOLDING IT LIKE I WOULD HOLD A BABY.
(http://www.dotheton.com/gallery/111030-061117221610.jpeg)

I FINALLY ARRIVED AT THE PISTONS AND CRANK. THAT SPACE WHERE THE BIG END BOLTS ARE IS PRETTY TIGHT!
(http://www.dotheton.com/gallery/111030-061117221746.jpeg)

VALVES DISASSEMBLED. ENGINE PULLED APART COMPLETELY. WHAT NOW?
(http://www.dotheton.com/gallery/111030-061117221929.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: The Limey on Nov 07, 2017, 06:22:37
I've a soft spot for the old plastic maggot. I'm in.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: stroker crazy on Nov 07, 2017, 08:13:04
I do however know how to read a manual …

A good place to start!

Welcome to the forum. This is the best place on the net for advice about pretty much any bike problems, and without too much in the way of ego issues.

Know next to nothing about the CX myself, except that the seat is one of the ugliest things I have ever seen.

Good luck with the build.

Crazy
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Nov 07, 2017, 08:16:35
did you save the small oil metering orifice from the front transmission support plate

part number 4 in this diagram they escape quite easily and bad things result

https://www.partzilla.com/catalog/honda/motorcycle/1980/cx500d-a-deluxe/cylinder-block
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 07, 2017, 17:36:46

........................ advice about pretty much any bike problems, and without too much in the way of ego issues.

............................ the seat is one of the ugliest things I have ever seen.

Good luck with the build.

Crazy

Yes. It seems the poor ol' CX is the Shrek of the bike world. Ugly such that only a mother could love, yet with a devoted following it appears.
I have been encouraged from the posts that I have read at the patience, enthusiasm and spirit of cooperation apparent in the responses. As an apprentice........I think I'm in the right place.
Thanks.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 07, 2017, 17:49:43
did you save the small oil metering orifice from the front transmission support plate
............................... they escape quite easily .........

Thanks Man (CXMan)
Good call. I did save the 3 oil orifice tubes, 1 at the transmission block, and 1 each at the cylinder heads. But I did lose a locating dowel for the rear cover. One stayed in the case, but the other went walkabout.
I measured the one I had and it was 9.97mm OD x 14mm long. I found one on ebay 10mmx14mm for a Honda postie but after looking at the Partzilla diagram it seems they are 8x14mm. I'll wait till I get ir to see if it fits.

That's a great resource. I had found David Silva, CMS and Wemoto, but Partzilla seems to have the little things, like dowels and Orings.

Thanks again CXMan!

PS: what do those oil tubes actually do??
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Nov 07, 2017, 18:53:35
that is not what i a m talking about the part that gets lost if a aluminum part it looks like a short bullet and it has a metering hole thru it

scroll down thru this you will see it sitting in a picture by itself and where it goes

https://motofaction.org/motorcycles/honda-cx-gl/replacing-front-engine-cover-what-check-honda-cx500-gl500-cx650-gl650/
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: irk miller on Nov 07, 2017, 21:21:51
(https://motofaction.org/sites/motofaction/files/sync/honda-cx500/replacing-front-engine-cover/how-replace-front-engine-cover-checks-before-o-rings-dowels-gasket-reinstall-honda-cx500-gl500-cx650-gl650-motofaction-org-7.jpg)

(https://motofaction.org/sites/motofaction/files/sync/honda-cx500/replacing-front-engine-cover/how-replace-front-engine-cover-checks-before-o-rings-dowels-gasket-reinstall-honda-cx500-gl500-cx650-gl650-motofaction-org-8.jpg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: spotty on Nov 08, 2017, 00:29:40
welcome from sunny (today anyway) Melbourne, you'll find a few folk on here who share your unaccountable love for the maggot and have done some nice things to them. theres a few cafe'd ones getting round Melbourne too
good luck and look on the bright side, it can't end up any uglier than when it left the factory
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 08, 2017, 04:18:33
that is not what i a m talking about

Got it. Thanks. I did save it.

(http://www.dotheton.com/gallery/111030-081117021521.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Nov 08, 2017, 07:42:04
if that little part does not get back in you wont have full oil pressure and the cam journals will be running dry

and the block gets ruined quickly
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: tattoo on Nov 08, 2017, 15:37:51
Spotting a CX500/GL500 project always halts me in my tracks....they can be transformed into really interesting machines.

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 11, 2017, 05:35:18
Shedding the water pump, stator, and rear cover. It's slow progress.

https://youtu.be/YVJT2PjNNBM (https://youtu.be/YVJT2PjNNBM)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 16, 2017, 19:42:18
Below are the last videos of the engine dismantling process.

I have now completed the rebuild and have posted a log in the Engines section, but here is a link:

http://www.dotheton.com/forum/index.php?topic=74854.0



https://youtu.be/1Di8G3sqfXM (https://youtu.be/1Di8G3sqfXM)


https://youtu.be/xwyvs4-QY2Y (https://youtu.be/xwyvs4-QY2Y)


https://youtu.be/HzX1SXnQKJQ (https://youtu.be/HzX1SXnQKJQ)


https://youtu.be/B_hUdxi9JKE (https://youtu.be/B_hUdxi9JKE)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Nov 24, 2017, 17:57:46
So the engine and bike are dismanteled.
Now to start with painting engine parts.

I used VHT engine enamel primer and Black pearl.

I have been told that spray can paint won't last.
I have no previous experience with painting engines. Any comments?

Here is the video .



https://youtu.be/giecOYmFjS4 (https://youtu.be/giecOYmFjS4)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Nov 24, 2017, 18:22:37
if its all stripped get it powdercoated
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 04, 2017, 06:41:36
With the engine completely pulled apart and cleaned, it's time to start checking engine parts for wear and if still within tolerances as per figures given in the manual. A set of vernier calipers, micrometers, bore gauges, thickness gauges, and plastigauge was an essential, if slightly costly investment.

Here's the detailed video.


https://youtu.be/ZyaBBrhYVOI (https://youtu.be/ZyaBBrhYVOI)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 08, 2017, 17:17:20
Time to start putting the engine back together.
Could only get one size of bearing shell for the big ends.....This engine used a different size for each piston (one green and one yellow).
The one that needed the yellow but got the green shells instead ended up with a pretty tight oil clearance at the crank pin. The tolerance is between 0.028 and 0.052mm, with a service limit of 0.080mm.
The tight one ended up around the 0.030mm using Plastigauge for verification. Let's hope it works. May need an extended breaking in period.
By the way....I'm not setting any speed records here.



https://youtu.be/IAN8QsVAzq0 (https://youtu.be/IAN8QsVAzq0)


https://youtu.be/F93EcRvK9YA (https://youtu.be/F93EcRvK9YA)


https://youtu.be/BCj2_vkPLWw (https://youtu.be/BCj2_vkPLWw)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 15, 2017, 07:00:16
With the engine rebuild complete, it was time to see how the maggot was going to start looking.

(http://www.dotheton.com/gallery/111030-151217032046.jpeg)


So I laced up the front wheel. Its a Sun 2.75 x 18 rim with a Cognito conversion hub.

(http://www.dotheton.com/gallery/111030-151217032134.jpeg)


Fitted the tube and tyre - an Avon AM26 Roadrider 110/80 x 18

(http://www.dotheton.com/gallery/111030-151217032242.jpeg)


A pair of USD forks from a 2007 GSXR-600, and Cognito top and bottom clamps and stem to complete the front end conversion.

(http://www.dotheton.com/gallery/111030-151217032345.jpeg)


.....and corresponding axle to go with it.

(http://www.dotheton.com/gallery/111030-151217032540.jpeg)


Front end assembled

(http://www.dotheton.com/gallery/111030-151217032627.jpeg)


Bottom clamp has adjustable turn stops

(http://www.dotheton.com/gallery/111030-151217032708.jpeg)


The top clamp has slots for Motogadget instrument and lights

(http://www.dotheton.com/gallery/111030-151217032744.jpeg)


Starting to take shape now.

(http://www.dotheton.com/gallery/111030-151217032839.jpeg)


I have no fabrication experience so I bought the seat and cowl. This one is by Cafe Racer KIts. It's their Roadster version. I'm still not sure if I like it. Its a great and comfortable seat but I find it too high........

(http://www.dotheton.com/gallery/111030-151217032921.jpeg)


.....but the I do like the shape of the cowl. Maybe I'll try my hand at fabricating a seat that is lower and shows off more of the cowl shape.

(http://www.dotheton.com/gallery/111030-151217033000.jpeg)

(http://www.dotheton.com/gallery/111030-151217033028.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: irk miller on Dec 15, 2017, 10:28:14
From here, it just looks like you need to adjust the bottom edge profile of the seat to match the frame.  The frame has substantially more curve than the seat.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 15, 2017, 11:54:21
That's looking pretty impressive. CX is a good motor after waterpump seal and cam chain tensioner are done. It actually lasts much longer if you keep it around 6,000rpm or more, at low engine speeds it self destructs cam chain tensioners, sometimes taking out the case. The last models (+CX650+ had an automatic tensioner which lasts about 18,000 miles but a lot longer if you check at every service to make sure it's adjusting..
I guess you'll have a pair of plates made to convert rear wheel to spokes? (cut original 'spoke' bolts, bolt on plates, lace up)
Personally, in my experience, except for the original styling, the 'Plastic Maggot' isn't a bad bike, the motor is much easier to work on than any of the in-line fours and only takes about 20 mins to get 'on the bench' (after a bit of practice). Second year in Britain, the addition of fly-screen changed the look more than anyone thought possible. It even handled reasonably well (particularly for the time period)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 15, 2017, 21:27:15
From here, it just looks like you need to adjust the bottom edge profile of the seat to match the frame.  The frame has substantially more curve than the seat.

Thanks Mr Miller. Do you mean to follow the frame line as I've drawn down below?

(http://www.dotheton.com/gallery/111030-151217192445.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: irk miller on Dec 15, 2017, 21:29:41
Yep.  I'm reaching from a distance, but I assume since it's a fiberglass base, you can shave some off to match the frame better.  Looks to me like the tail section may need it more than the front half, so it lowers the angle of the seat.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 15, 2017, 21:47:13
That's looking pretty impressive. CX is a good motor after waterpump seal and cam chain tensioner are done. It actually lasts much longer if you keep it around 6,000rpm or more, at low engine speeds it self destructs cam chain tensioners, sometimes taking out the case. The last models (+CX650+ had an automatic tensioner which lasts about 18,000 miles but a lot longer if you check at every service to make sure it's adjusting..
I guess you'll have a pair of plates made to convert rear wheel to spokes? (cut original 'spoke' bolts, bolt on plates, lace up)
Personally, in my experience, except for the original styling, the 'Plastic Maggot' isn't a bad bike, the motor is much easier to work on than any of the in-line fours and only takes about 20 mins to get 'on the bench' (after a bit of practice). Second year in Britain, the addition of fly-screen changed the look more than anyone thought possible. It even handled reasonably well (particularly for the time period)

Thanks for the comment crazypj. This is a 1982 500 Shadow Australian model, and I don't know if had been upgraded along the way, but when I opened it it turned out to have an auto cam chain tensioner.

(http://www.dotheton.com/gallery/111030-151217192526.jpeg)

 I replaced the cam chain anyway since I didn't know what life it had, and since the back cover was off, I also changed the oil and mechanical seal on the water pump. I also replaced the gear change lever rod seal and the final drive seal.

I don't have a lot of experience working with engines but I found this engine relatively straight forward to work with, but without the manual I would have been lost, and I can't wait to test it out on the finished build. I only got to ride it around the block when I got it as the clutch was stuffed.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 15, 2017, 21:49:51
Yep.  I'm reaching from a distance, but I assume since it's a fiberglass base, you can shave some off to match the frame better.  Looks to me like the tail section may need it more than the front half, so it lowers the angle of the seat.


You're spot on. Its a fibreglass base, and I agree that the tail looks to high. I don't have any shocks on and the bike is on its centre stand, which is pushing tail up a bit, but I do agree that I have to work on the seat base.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 16, 2017, 13:28:27
Personally I would cut some semi-circular clearance around top of shocks to allow rear of seat to sit substantially lower The angle at present is more reminiscent of German 'Streetfighters' from 90's. Bottom of tank 'slopes' down so you can't really follow it's line
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 17, 2017, 08:42:17
no american 500s had the auto tensioner  the 650s did

the austrailian shadow 500 of that year all had it as did europe and pacific rim
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 17, 2017, 16:48:44
Interesting, I did not know that
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 17, 2017, 17:14:28
My understanding was that the original (manual tensioner) cam chain guide bolt would loosen, but that Honda did offer a recall and upgrade. Don't know much else with respect to the different regions or when they switched to the auto tensioner, which I also understand is trouble free.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 17, 2017, 17:49:44
I was working at Honda dealers when CX was launched, Honda ran one CX motor at 10,000 rpm for a week, (non stop on dyno) stripped it to measure wear, didn't find anything significant so thought bike was ready for general public. They expected people to 'mistreat' motor and use high rpm. Unfortunately, people teated it like a Harley and rode around in high gears at 'low' rpm. It was found the load reversals were causing cam chain flutter' which was breaking stuff (Harley had / has same problem with twin cam for same reasons)  I did way too many CX's under guarantee / recall including crankcase changes when the mounting bosses broke off.
 Officially, there were only 3 types of cam chain tensioner but I know in Britain we had at least 5 different types while factory was re-designing things.
The automatic is the best  but an oil assist( if it had been available) would have been better.  Luckily Honda still machined the inspection plug so it is possible to check tensioner operation
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 18, 2017, 07:39:11
there never was a upgrade to the auto tensioner it cant be done simply

the crank support plate that holds the main bearing is different

the block is tapped for a different support and guide pin

the timing chain guides are different

the manual timing chain bolt has NEVER had a problem coming loose

the chain has way more adjustment (longer life) with the manual system

it is not to hard to convert them back to manual adjust i do this in high performance bikes and

racing 650 as the manual adjust system is stronger the auto tension system gets bet to death and fails

if it is left with a worn chain and gets beyond adjustment it will fail spectacularly
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 18, 2017, 07:41:45
ps you cant see the indicator hole in the auto tensioner thru the timing port

even with a modern camera
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 18, 2017, 07:58:38
No. I meant that Honda did an upgrade to the problematic early manual tensioner with a solution....not an auto tensioner.
So what was the problem with the early manual tensioner that has become part of CX folklore? Was thete a problem....was there a solution?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 18, 2017, 11:33:12
Personally I preferred the manual tensioner BUT, if you don't check every 1500~2000 miles it can get 'sticky.'
Check the operation of it by removing inspection cover, I used to 'rock' crank back and fore with lock bolt 'loose' to maker sure it was actually moving then turn to tightest position before re-locking. I seem to remember the manual instructions were not completely clear on adjustment or were confusing which is why so many got it wrong?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 18, 2017, 13:45:25
22thousand 1978 bikes ONLY

had a early chain guide plate that in one instance allowed the chain to snap locking the rear wheel and causing one death

it resulted in the 22k bike having a NTSB recall issued where the chain guides guide plate and upper re enforcing tab

were replaced

that was it

all the rest if mis information

to set the manual tensioner

put left piston to tdc firing

loosen the adjuster screw 1.5 turns

take a block of wood put it up against the side of the motor close to the adjuster screw

tap the wood block a few times

tighten the screw with a torque wrench

do this every i change and valve setting

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 18, 2017, 18:41:46
Thanks for clearing that up cxman.

You are right...there is a plethora of misinformation and the tricky thing is deciding who and what to believe.  ;)

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 18, 2017, 21:44:16
22,000 total or in USA? Never mind, I looked it up, about 50,000 were made in 1978
In Britain it was an issue for more than a year. and recurred around 18~19,000 miles on any model driven 'gently'
The answer is to beat the hell out of it  ;D
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 19, 2017, 07:25:15
the real problem was a new chain stretches the most at the beginning of its life

most of the dealers were not doing the timing chain adjust till the 4500 mile service (if by  then the customers brought them back)

so the chains got loose and slapped around and ate the crank support plate

or broke a guide

new chain needs an adjust at 250 500 1000 then 2000 then back to regular adjustments
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 19, 2017, 15:53:51
So with an auto tensioner I don't have to worry about that but should replace chain at, say 50,000 km ?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 20, 2017, 18:41:23
it wont last anywhere near 50 k

maybe 30 but i would start listening after 23k you ca hear them when they start to bounce
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 20, 2017, 18:46:34
Will do. Thanks for the tip!
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 26, 2017, 04:12:57
Trying to finish off engine over weekend. I replaced the water impeller, reusing the old copper washer after annealing to restore malleable properties, and then the case with a new rubber seal...

(http://www.dotheton.com/gallery/111030-261217014728.jpeg)

(http://www.dotheton.com/gallery/111030-261217014803.jpeg)

Checked to make sure there was no binding by rotating the crankshaft. No problems.


Then the transistorized ignition pulse generator at the rear of the engine case.....

(http://www.dotheton.com/gallery/111030-261217021036.jpeg)

....and set the timing. All good so far.

When I went to place new gasket, discovered that I had one or the CDI versions of the CX500.

(http://www.dotheton.com/gallery/111030-261217015415.jpeg)

In Australia, it appears that honda introduced the Transistorized ignition version that was not available in the US, until the GL versions came on board. The pulser cover is different, and needs a different gasket. One's on it's way.

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 26, 2017, 04:14:08
I was reading up a CX500 article that after reassembling rear cover, one should temporarily refit the gear change lever and test to make sure gears are changing. This can be done by working the output shaft back and forth whilst changing gears. I got it into first, then could not get it out of first.

Turned out, with help from members of the CX500 forum, that when inserting the back case and threading the gearshift spindle, DO NOT BACK OUT....or the selector gears may disengage.

I had to remove the water impeller, the pulse generator, the rear cover.

When I fitted the gear selector initially, it looked like this...

(http://www.dotheton.com/gallery/111030-261217020119.jpeg)

But when I removed the case, it looked like this...

(http://www.dotheton.com/gallery/111030-261217020041.jpeg)

Anyway, I replaced the gears correctly, carefully refitted the back case, tested the gears, and all was good with the world again.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 26, 2017, 04:23:00
The engine is resting for now. Time to move on with the modifications to the frame I need to do before sending to powder coating.

I prepared this fibreglass rear hugger that I bought from Cafe Racer Kits. I just needed locating then welding the support tabs onto the swing arm.

(http://www.dotheton.com/gallery/111030-261217021725.jpeg)

(http://www.dotheton.com/gallery/111030-261217021751.jpeg)

(http://www.dotheton.com/gallery/111030-261217021923.jpeg)

(http://www.dotheton.com/gallery/111030-261217021953.jpeg)

(http://www.dotheton.com/gallery/111030-261217022016.jpeg)

Had I been a fabricator, I would have made one myself. Perhaps at the next build.....whatever that may be? Needles to say, I'm hooked and keen to learn more and expand my skills.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 27, 2017, 05:18:52
I still have to complete a few other additions and modifications so I can get frame painted.

Today it was key relocation.

With the new front end and upper triple clamp, I lost the location for the key drum. I don't want to clatter up the area so it's going under the seat. But most of all, 'cause it looks cool!

This is the extent of my fabrication skills to date.

(http://www.dotheton.com/gallery/111030-271217025925.jpeg)

(http://www.dotheton.com/gallery/111030-271217030008.jpeg)

(http://www.dotheton.com/gallery/111030-271217030037.jpeg)

(http://www.dotheton.com/gallery/111030-271217030110.jpeg)

Now I have to figure out how to hang the choke, which was previously hooked on the handle bar assembly. Any suggestions?

(http://www.dotheton.com/gallery/111030-151217032744.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 27, 2017, 05:21:53
I had a bit of time left so I trimmed the fibreglass seat pan (from CRK-UK).

(http://www.dotheton.com/gallery/111030-271217030226.jpeg)

(http://www.dotheton.com/gallery/111030-271217030257.jpeg)

(http://www.dotheton.com/gallery/111030-271217030330.jpeg)

(http://www.dotheton.com/gallery/111030-271217030406.jpeg)

(http://www.dotheton.com/gallery/111030-271217030439.jpeg)

(http://www.dotheton.com/gallery/111030-271217030510.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 27, 2017, 05:30:39
I know there's still a lot to do, but at least it's starting to look like something after being a pile of parts for the best part of one year.

The rear sets are from Slipstream Cycle Works. They're perfect. Another indulgence but there was no way I was going to tackle conjuring up my own from universal sets generally available. I've been furiously reading forums and working with pencil on paper for the last 12 months trying to work on my own set.....this bike is a brain crusher.

The gearbox runs along long axis of bike, and the gear shift spindle comes out the back of the engine also running from front to back. Not like most bikes out there which come out the pointing to the side of the engine. It can be done, but it's a nightmare of linkages. I could have kept it stock.......but in for a penny......you know how it goes.

(http://www.dotheton.com/gallery/111030-271217030544.jpeg)

(http://www.dotheton.com/gallery/111030-271217030844.jpeg)

(http://www.dotheton.com/gallery/111030-271217030915.jpeg)

Next stop..... Convert rear Comstar to spoked wheel with bolt on flanges (also CRK-UK) so hub can also be painted........then carburetor overhaul.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 28, 2017, 20:34:24

When I'm a bit tired and don't want to tackle the bigger things, I find polishing bits very therapeutic.

It's not too brain consuming so I can think of the bigger tasks ahead.

(http://www.dotheton.com/gallery/111030-281217182150.jpeg)

I was going to paint these black like the rest of the engine, but they are such beautiful and intricate visible pieces that I thought...NO...show them off!

(http://www.dotheton.com/gallery/111030-281217182303.jpeg)

For those not familiar with the CX500 V twin, they are brackets for a coolant pipe (see below)

(http://www.dotheton.com/gallery/111030-281217182943.jpeg)

And I finally finished detailing the oil filter housing. I couldn't finish the black edges as well as I wanted to..............Actually, it wasn't that I couldn't......sometimes you have to know when to quit. From a reasonable distance, one can't tell.

(http://www.dotheton.com/gallery/111030-281217182338.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 30, 2017, 05:07:54
What does one do with a perfectly good rear Comstar? Chop it...of course.

Many will be familiar with a bolt on flange conversion to a spoked wheel.

In this case, I am freeing the rear hub from the wheel to ready for some bolt on flanges supplied by CRK.

I will then be lacing to a Sun gold anodized 3.5 x 18 rim with some chromed spokes.

This is the conversion process....I begin by removing everything from the wheel to make it ready.

(http://www.dotheton.com/gallery/111030-301217025020.jpeg)

Removing the final drive flange

(http://www.dotheton.com/gallery/111030-301217025058.jpeg)
(http://www.dotheton.com/gallery/111030-301217025131.jpeg)

Drifting out bearing on drive side

(http://www.dotheton.com/gallery/111030-301217025202.jpeg)

Bearing and spacer.

(http://www.dotheton.com/gallery/111030-301217025231.jpeg)

Don't have the specialty tool to remove the bearing retainer on brake side. I concocted this bizarre contraption using 2 nuts and an expanding bearing puller. The aim was to lock the nuts against the inner surface of the retainer and then unscrew.

(http://www.dotheton.com/gallery/111030-301217025302.jpeg)

IT DIDN'T WORK!  :'(

But I did find something that did. Circlip pliers.

(http://www.dotheton.com/gallery/111030-301217025331.jpeg)

The break side bearing can now be drifted out.

(http://www.dotheton.com/gallery/111030-301217025401.jpeg)

Remove the tire, and the wheel is now ready for butche........I mean refurbishing.

(http://www.dotheton.com/gallery/111030-301217025432.jpeg)

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 30, 2017, 05:17:37
WARNING : THE FOLLOWING PHOTOS CONTAIN IMAGES THAT MAY UPSET SOME VIEWERS!

Cut the alloy spokes on both sides.

(http://www.dotheton.com/gallery/111030-301217025510.jpeg)

Grind off heads of bolts, taking care not to grind into the hub.

(http://www.dotheton.com/gallery/111030-301217025542.jpeg)

Drift the bolts out.

(http://www.dotheton.com/gallery/111030-301217025609.jpeg)

And here's the hub freed from the wheel.

(http://www.dotheton.com/gallery/111030-301217025637.jpeg)

These are CRK supplied flanges. They go into the pile for painting.

(http://www.dotheton.com/gallery/111030-301217025821.jpeg)

For the front wheel, I used a Cognito CX to GSXR conversion hub, Sun rim and chromed spokes. Here a little video how to lace the wheel.

https://youtu.be/PyfhdzY6KIA (https://youtu.be/PyfhdzY6KIA)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: der_nanno on Dec 30, 2017, 11:31:11
Those flanges look simple enough to copy...  :)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 30, 2017, 12:52:31
they may be simple to copy and that is what is happening

but i have seen some crack already from flexing from the spoke holes out

and i have seen a few loose

spoke wheels flex a lt and need constant checking

i wont use these on a build even if a customer buys them i wont install them just my opinion
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: der_nanno on Dec 30, 2017, 16:56:34
From an engineer's point of view: Material selection will be important, the design itself is rather simple in CAD.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 30, 2017, 17:50:44
From an engineer's point of view: Material selection will be important, the design itself is rather simple in CAD.

I agree with you der_nanno - as long as you have an understanding of the material's properties and the stresses involved, why not? If you don't, you can either ask someone who knows, or buy from someone who does.

After all, this forum is partly about choppin'n'changing. If it's dangerous conditions that are at issue, I would say that more catastophies occur from riders smiling so much that their brains turn off, rather than mechanical catastrophic failures. But I don't know that for certain!
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 30, 2017, 17:58:03
they may be simple to copy and that is what is happening

but i have seen some crack already from flexing from the spoke holes out

and i have seen a few loose

spoke wheels flex a lt and need constant checking

i wont use these on a build even if a customer buys them i wont install them just my opinion

Fair comment CXman, you obviously have a lot of experience with these bikes.

But when you say you won't use these, and that you've seen some crack, are you specifically referring to those supplied by CRK? The reason I'm asking is that if that is not the case, the comment may end up damaging someone's business, even if you qualify it with a "my opinion" at the end. This is not an attack on your comment, but I feel it requires clarification.

Please note I have no financial or other association with CRK - merely a satisfied customer.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 30, 2017, 18:25:45
here is the issue

no one has done a stress test on any of these discs they are not an "engineered solution"

that was arrived at by calculating the strength or field testing or non destructive testing required for any other wheel

they are sold as a accessory yet are what you stake your life on and you do the installation of

you bought them and are installing them and think they ar ea great thing

but have no idea about the flex and torsional twist a spoke suffers

and how important it is for the spoke holes to be champhered exactly how the spoke faces ect

last but no least i did not mean to imply that crk just copied someones spoke plates

but they copied the idea that motosynthesis brought out years ago

and they do crack


 



Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 30, 2017, 18:39:04
You are right of course CXman. I don't have any idea so I rely on the knowledge and experience of others. I won't be selling this bike, so I will be able to inspect and react for the life of the bike whilst I live. Thanks for you insights.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Dec 30, 2017, 20:16:30
Do keep an eye on them and i wish you a lifetime of joy

And safety
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: The Limey on Dec 31, 2017, 03:41:09
Although chicks find the danger sexy, so there's a balance to be struck ;)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Dec 31, 2017, 03:51:12
Although chicks find the danger sexy, so there's a balance to be struck ;)

Spot on.
But this is going to be a single seater, so if you're referring to poultry sitting on my shoulder..................
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Dec 31, 2017, 13:33:14
If those flanges are cast then machined, I probably wouldn't use them either, too much localised stress around mounting bolts in my opinion although spoke holes should be fine.
If they are 6061 T6, about 1/4" thick then hard anodised they will be MUCH stronger than the cast hubs 'everyone' used from 60's to 2000+ (and still use today)
7075 would be even stronger either will bend rather than crack. I would make my own if I was in the market for a par as I would then know exactly what has been done and the material.
Spoked wheels will need checking after 100 and 500 miles then will probably be fine for next 50,000 or more miles (in my experience of aluminium alloy rims)
MX and Enduro bikes are the only ones that can need wheel maintainance every week / month / ride( when 'used properly'  ;) )
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 01, 2018, 16:37:56
Cx 500 is the most versatile, easy, pleasant to work on motorcycle ever made. Everthing is accessible... way the frame is built around the engine. I have had 3/4 of these bikes. I move on to kawa gt750 project now as I prefer a shaft driven bike. I always look back and think how pleasant a cx is to work with!


Sent from my iPhone using DO THE TON
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 01, 2018, 17:13:11
I agree morgs88. I have not had experience working on any other bikes. This is my first....but I'm  having a hoot of a time working on this one.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 01, 2018, 17:24:57
Parts are so easy to get hold of. What are turning your cx into? Cafe/tracker??


Sent from my iPhone using DO THE TON
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 01, 2018, 17:32:08
More of a roadster/cafe mix.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 01, 2018, 17:33:02
Is that your CX posted im bike of the month thread?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 01, 2018, 17:33:51
Is that your CX posted im bike of the month thread?

It is yes


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 01, 2018, 17:35:58
You have a build thread?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 01, 2018, 21:10:28

The battery box.

This is one supplied by CRK, and it's designed to go under the engine in place of the H box. It's designed for a Lithium ion battery which can be turned on its side, and has a bracket for the started solenoid rubber mounts.

My knees are not as good as once were, so I'm trying to keep things that may need service access as high as possible.

There is a bit of room under the seat support, so I decided to modify the box to fit there instead. In either case, I'm going to have to extend the leads to the starter motor and find a new route for the secondary loom.

(http://www.dotheton.com/gallery/111030-010118185648.jpeg)

I'm drilling some holes in the seat support, and will use a threaded rod with nuts on each side for the rear mounts in the battery box. This will allow box to swivel down and give access to fit battery.

(http://www.dotheton.com/gallery/111030-010118185718.jpeg)

But then I realized that the box ended up too deep under the seat support, and did not allow placement of started solenoid in bracket.

So I made another hole. What's the saying?......measure once, and cut twice?

(http://www.dotheton.com/gallery/111030-010118185749.jpeg)

That's better. I also welded some tabs to allow back of box to be fixed to existing holes in loop frame.

(http://www.dotheton.com/gallery/111030-010118185827.jpeg)

(http://www.dotheton.com/gallery/111030-010118185854.jpeg)

It's not invisible....but it ain't ugly.

(http://www.dotheton.com/gallery/111030-010118185924.jpeg)

And that's the last thing to do before painting or powdercoating frame. My budget is starting to get a little thin after all the goodies I bought for this build, so I'm off to the powdercoaters for a quote, but if too expensive, will consider painting myself. Painting's not my strong suite.....but look at how well Jackson Pollock did!
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 02, 2018, 03:08:11
You have a build thread?
I don’t have one no...
I am never very clued up with phones. Have taken plenty of pics of the new project though


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 02, 2018, 03:09:22
The battery box.

This is one supplied by CRK, and it's designed to go under the engine in place of the H box. It's designed for a Lithium ion battery which can be turned on its side, and has a bracket for the started solenoid rubber mounts.

My knees are not as good as once were, so I'm trying to keep things that may need service access as high as possible.

There is a bit of room under the seat support, so I decided to modify the box to fit there instead. In either case, I'm going to have to extend the leads to the starter motor and find a new route for the secondary loom.

(http://www.dotheton.com/gallery/111030-010118185648.jpeg)

I'm drilling some holes in the seat support, and will use a threaded rod with nuts on each side for the rear mounts in the battery box. This will allow box to swivel down and give access to fit battery.

(http://www.dotheton.com/gallery/111030-010118185718.jpeg)

But then I realized that the box ended up too deep under the seat support, and did not allow placement of started solenoid in bracket.

So I made another hole. What's the saying?......measure once, and cut twice?

(http://www.dotheton.com/gallery/111030-010118185749.jpeg)

That's better. I also welded some tabs to allow back of box to be fixed to existing holes in loop frame.

(http://www.dotheton.com/gallery/111030-010118185827.jpeg)

(http://www.dotheton.com/gallery/111030-010118185854.jpeg)

It's not invisible....but it ain't ugly.

(http://www.dotheton.com/gallery/111030-010118185924.jpeg)

And that's the last thing to do before painting or powdercoating frame. My budget is starting to get a little thin after all the goodies I bought for this build, so I'm off to the powdercoaters for a quote, but if too expensive, will consider painting myself. Painting's not my strong suite.....but look at how well Jackson Pollock did!
What size battery are you using? How much do you boys pay for the lithium batteries and chargers over in oz


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 04, 2018, 02:57:49
What size battery are you using? How much do you boys pay for the lithium batteries and chargers over in oz


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I believe it's a YT9B-4   150x69x105mm. Haven't bought one yet so don't know price.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 04, 2018, 09:19:40
you may create problems for yourself and risk stator damage

YT9B-4 only offers 115cca

cx500 should have 180 min 200cca  preferred

its a 8 amp hour and a cx is supposed to have a 14ah 
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 04, 2018, 21:33:10
EarthX ETX18B ?.....not cheap...but then...its probably the most important component in the bike.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 05, 2018, 11:49:12
the ETX12A  would do it for a 500 unless you ride in cold weather
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Jan 05, 2018, 18:17:43
To be fair these gel batteries have a awesome output for a little battery. Long as stator/regulator/rectifier doing its job as long with manget generator and juices battery back up. Shouldn’t matter too much what size you use really? Any doubts bang it on trickle before a ride day before


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 05, 2018, 18:55:49
its starting it without hurting theh starter

and if its o low a amp it may hurt the stator
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 05, 2018, 19:05:20
Yep. I'll get the ETX12A and thinking of upgrading reg/rect to a MOFSET to better protect circuit.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 05, 2018, 20:23:05
you have to go mofset to safely run that on a cx
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Jan 08, 2018, 20:35:47
its starting it without hurting theh starter

and if its o low a amp it may hurt the stator

Starter will probably be fine, the starter relay will 'rattle' if battery can't keep up and contacts burn away. (When battery is marginal there is enough  power to close relay contacts, when starter motor engages the sudden current drop makes relay 'drop out'' and start all over again) Due to the internal 'stop bar' relay can still sound OK but cannot make electrical contact
Problem is usually the initial starting current. On an inline 4 between 600~1000cc it usually starts around 70~90 amps then stabilises as motor is turning over and needs about 35~50 amps.
115 CCA 'should' in theory be plenty to start a CX500, but, slightest issue (or even cold start) can be enough to drain battery. Having an OFF switch for headlight will lower draw by at least 5 amps. Fitting LED's 'everywhere else' will give plenty of charge after bike is running. I forget if CX is 'star' or 'delta' wound,
( I think 'star' as it's 'better' for high (3,000+) rpm applications )
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 09, 2018, 08:36:33
the cx500 is 10.5 to one compression and has a large rotor flywheel close to 7 lbs so it takes a bit of oomph

Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on Jan 09, 2018, 11:25:03
It's easier to put an ammeter in the circuit to test  ;) .
Even a cheap automotive one will give a real good idea of whats going on. I keep a couple with extension leads and alligator clips for testing various 'high amp' components. You can also use a shunt and ordinary multimeter. Easy shunt is 19" of 6 gauge wire, (measuring points are at 19") You'll get millivolts (or milliamps, it's years since I did this) which translate to direct amp load in shunt. I guess you have a couple of runners?
 It only takes a few minutes to set up and test
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Jan 09, 2018, 15:04:22
Or just get the bigger capacity battery to be sure.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on Jan 09, 2018, 17:31:34
"Or just get the bigger capacity battery to be sure."

Yup
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Feb 04, 2018, 04:46:08
(https://uploads.tapatalk-cdn.com/20180204/3a21d2bfa56c7f41870196d49fced925.heic)(https://uploads.tapatalk-cdn.com/20180204/4cb3d565d45b194b9c82d22422f24b59.heic)

Ride out today auto jumble and bike meet today


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: morgs88 on Feb 04, 2018, 14:03:51
Blue nylon lockers shall be picked up
Tomorrow I knew I should
If used them... bracket came off on way home!!! Had to ride 45 mins no plate or rear light!! (https://uploads.tapatalk-cdn.com/20180204/67fb2f872fc7fbecc3fac807753c085a.heic)


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Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Feb 04, 2018, 15:25:30
Oops.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Feb 13, 2018, 03:20:17
So continuing with the electrical aspects, I've laid out where things are to be mounted.

I've got this so far.

(http://www.dotheton.com/gallery/111030-130218010421.jpeg)

The spark units are a little far from the connectors on the loom. I think the idea of using the existing loom without alteration is a gonner.

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.

(http://www.dotheton.com/gallery/111030-130218010555.jpeg)

(http://www.dotheton.com/gallery/111030-130218010709.jpeg)

I could make new mounts, or drill out the holes in the regulator to fit........but after previous comments on upgrading the battery to a Lion battery, it seems that I will have to upgrade the regulator to cope with the extra juice generated, to prevent battery burnout.

I ended up buying a MOSFET regulator from Roadster Cycles.

(http://www.dotheton.com/gallery/111030-130218011847.jpeg)

Rethink location and drill new mounts.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Feb 13, 2018, 03:26:19
I finally managed to finish preps for all the parts to be sent to powdercoating.

I remembered seeing a youtube by Ginger Geordi Biker and his CX500......he got his frame back from powdercoaters but the coating covered the threaded mounts and he couldn't get his bolts on. Nothing that a tap can't fix, but I thought I'd beat the problem and so I placed bolts and nuts in every mount. Several of them are M10x1.25......not your common garden variety type, but was able to source some cheap ones at Super Cheap Autos.

The parts were delivered last week and I will have them ready to pick up at the end of the week.

(http://www.dotheton.com/gallery/111030-130218012230.jpeg)

(http://www.dotheton.com/gallery/111030-130218012200.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on Feb 13, 2018, 03:34:00
That previous post was a couple of weeks ago, and still waiting for frame to return from powdercoaters, and also for some parts to arrive.

It's been a while since I did much "real" work on the bike, so I decided to tackle some smaller things that could be started and finished within a couple of hours.

For those in the northern hemisphere too cold to go into their workshop, we in the south are experiencing some polar cap meltdown temperatures that are feeding your record snowfalls. It's all water after all. Bottom line is that I can't spend more than 2 hours in the shed before heatstroke sets in. Today was a little better so I chanced a small escapade.

First, some of you may recall that I butcheXXXX.......... dismantled the rear reverse comstar to salvage the hub. So today, I pulled the sandblasting box outside and prepped then painted it, as well as the radiator fan cowl.

(http://www.dotheton.com/gallery/111030-301217025542.jpeg)

(http://www.dotheton.com/gallery/111030-301217025637.jpeg)

(http://www.dotheton.com/gallery/111030-130218012816.jpeg)

(http://www.dotheton.com/gallery/111030-130218012849.jpeg)

(http://www.dotheton.com/gallery/111030-130218012918.jpeg)

I get the feeling that it's important to keep doing even small things, lest complacency set in and project becoming in danger of turning into storage and eventual fire sale.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist 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.

(http://www.dotheton.com/gallery/111030-130218013815.jpeg)

(http://www.dotheton.com/gallery/111030-130218013844.jpeg)

(http://www.dotheton.com/gallery/111030-130218013905.jpeg)


Ahh yes. I also cut the end of the camshaft. Mechanical cam driven fan out....electric temp sender operated fan in.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj 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.

(http://www.dotheton.com/gallery/111030-130218010555.jpeg)

(http://www.dotheton.com/gallery/111030-130218010709.jpeg)

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)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist 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.

(http://www.dotheton.com/gallery/111030-140518050036.jpeg)

Thanks CXPHREAK!

New bolt O ring...

(http://www.dotheton.com/gallery/111030-140518050111.jpeg)

New filter and housing O ring seal.

(http://www.dotheton.com/gallery/111030-140518050141.jpeg)

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

(http://www.dotheton.com/gallery/111030-140518050217.jpeg)

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

(http://www.dotheton.com/gallery/111030-140518050251.jpeg)

Nice little job to put me in the mood.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist 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.

(http://www.dotheton.com/gallery/111030-150518030914.jpeg)

(http://www.dotheton.com/gallery/111030-150518030945.jpeg)

(http://www.dotheton.com/gallery/111030-150518031018.jpeg)

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.

(http://www.dotheton.com/gallery/111030-150518031304.jpeg)

Correct bearings in hand. Still good.

(http://www.dotheton.com/gallery/111030-150518031332.jpeg)

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

(http://www.dotheton.com/gallery/111030-150518031359.jpeg)

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

(http://www.dotheton.com/gallery/111030-150518031424.jpeg)

Freeze outer race. Third attempt. No good.

(http://www.dotheton.com/gallery/111030-150518031447.jpeg)

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.

(http://www.dotheton.com/gallery/111030-150518031510.jpeg)

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

(http://www.dotheton.com/gallery/111030-150518031535.jpeg)

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.

(http://www.dotheton.com/gallery/111030-150518031625.jpeg)

(http://www.dotheton.com/gallery/111030-150518031712.jpeg)

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.

(http://www.dotheton.com/gallery/111030-150518031738.jpeg)

(http://www.dotheton.com/gallery/111030-150518032903.jpeg)

New outer race went in without dramas.

(http://www.dotheton.com/gallery/111030-150518032931.jpeg)

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.

(http://www.dotheton.com/gallery/111030-150518033000.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj 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)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist 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.

(http://www.dotheton.com/gallery/111030-160518022458.jpeg)

(http://www.dotheton.com/gallery/111030-160518022535.jpeg)

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

(http://www.dotheton.com/gallery/111030-160518022603.jpeg)

+ the retainer. Punched to prevent loosening

(http://www.dotheton.com/gallery/111030-160518022630.jpeg)

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

(http://www.dotheton.com/gallery/111030-160518022656.jpeg)

(http://www.dotheton.com/gallery/111030-160518022718.jpeg)

O ring

(http://www.dotheton.com/gallery/111030-160518022748.jpeg)

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

(http://www.dotheton.com/gallery/111030-160518022808.jpeg)

....and replace bolts to specified torque.

(http://www.dotheton.com/gallery/111030-160518022829.jpeg)
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman on May 16, 2018, 07:50:32
i hope you put some loctite on those flange  bolts
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on May 16, 2018, 08:09:43
No. FSM doesn't  mention it....but I can still do that...and I will. Thanks cxman.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: cxman 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
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj 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?
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: Odontologist on May 16, 2018, 21:21:30
Right again crazypj. Turns out the threads are stuffed. Retainer is made of a very soft material. Couldn't get it down all the way. I have ordered a new retainer from JC at bettysprocket.com.au who also stocks a fair few other parts for the CX family. Will replace it when new one comes in.
Title: Re: Am I the Pontius Pilate of this CX500?
Post by: crazypj on May 17, 2018, 17:27:48
I made a scraper for them (probably 1978~79?)Old Phillips screwdriver that was worn got ground to a 60 degree point to make a 'lathe' cutting tool (easiest way to describe it) heated end to red hot and bent 90 degrees. Made it easy to clean out dirty or damaged threads. I've still got it even though it's only been used twice in last 30 yrs  8) Just dug it out for a picture