Am I the Pontius Pilate of this CX500?

[cxman]

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

[tattoo]

Spotting a CX500/GL500 project always halts me in my tracks....they can be transformed into really interesting machines.

[Odontologist]

Shedding the water pump, stator, and rear cover. It's slow progress.

[Odontologist]

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

[Odontologist]

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 .

[cxman]

if its all stripped get it powdercoated

[Odontologist]

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.

[Odontologist]

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.

[Odontologist]

With the engine rebuild complete, it was time to see how the maggot was going to start looking.




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




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




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




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




Front end assembled




Bottom clamp has adjustable turn stops




The top clamp has slots for Motogadget instrument and lights




Starting to take shape now.




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........




.....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.

[irk miller]

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.