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Author Topic: Am I the Pontius Pilate of this CX500?  (Read 9293 times)

Offline Odontologist

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Re: Am I the Pontius Pilate of this CX500?
« Reply #40 on: Dec 20, 2017, 18:46:34 »
Will do. Thanks for the tip!
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 #41 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...





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.....



....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.



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.

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 #42 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...



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



Anyway, I replaced the gears correctly, carefully refitted the back case, tested the gears, and all was good with the world again.
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 #43 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.











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.
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 #44 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.









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

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 #45 on: Dec 27, 2017, 05:21:53 »
I had a bit of time left so I trimmed the fibreglass seat pan (from CRK-UK).











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 #46 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.







Next stop..... Convert rear Comstar to spoked wheel with bolt on flanges (also CRK-UK) so hub can also be painted........then carburetor overhaul.
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 #47 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.



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!



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



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.

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 #48 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.



Removing the final drive flange




Drifting out bearing on drive side



Bearing and spacer.



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.



IT DIDN'T WORK!  :'(

But I did find something that did. Circlip pliers.



The break side bearing can now be drifted out.



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



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 #49 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.



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



Drift the bolts out.



And here's the hub freed from the wheel.



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



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.

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

1982 Honda CX500 Roadster build