Honda VT500E Scrambler "Madzia"

Aussie Steve

As useful as an ashtray on a motorcycle!
G'Day to All,

Name is Steve, an Aussie living in Poland.
Last December I decided to beat the frigging winter blues and push myself to do something new.. buy and build a custom..

Before I jump into my thread I’d like to say a few things..
1. Holy shit there is some builder mastery and artistry flying around on this site.. Hive fives all round. I admire and aspire to the things I have seen. Keep it coming guys!
2. My mechanical knowledge is piss poor. I have only ever changed oil/plugs in a bike prior to this build. BUT that is why I took on this endeavour - to learn.
3. Frankly speaking I wish I read and knew this about DTT before I started my bike. I have made some huge cardinal sins and still dealing with them. I’m sure some members will just shake there heads in disbelief if they read my thread. But hey, live and learn, it’s been worth it. I’ve enjoyed the challenge.

That being said, I thought it was time to post my learning experience so other dudes don’t make the same f@ck ups like me!!!
I will add a few things to the thread that I have found useful along the way.

Let me get into the gritty stuff..
Why a Honda VT500E?
I wanted a bike that was different than most builds ie. Not a SOHC CB750 (Hey don't get me wrong. Dig ‘em and want one) Just wanted something smaller and affordable. So if I f__ked it up. I wouldn't cry too much about it. Also, I didn’t want anything too big because most of my riding will be spent slicing between cars in traffic.
Two days before Christmas I sourced a Honda VT500 EURO, The Ascots butt ugly sister. I liked the V twin engine and comfortable riding position and thought it would be good base to start. So I did. Ace!

I’m 10 months into the build, I drive 20km through midtown traffic to get to the garage where I store the bike. I can only understand and speak about 5% of the Polish language and my tools are limited. Also, just had my first kid. Little bugger steals some time too! Aint stopped me yet though! I’m committed :) & still have plenty of enthusiasm 8)

Gezzzz enough of the monologue hey…so last thing for today
If you are in Poland. Send me a shout out!

This is how it all began :


And for a fuckin laugh:
Check out the DIY arc welder I was using!! ;)


Thanks for reading and point out any blatant errors as I post.
I’ll throw more up here soon!
 
strang said:
Hiya
Something different, I'd love a v-twin cafe tracker.
Front drum brake? What year are these?
Thats not a drum brake, its a disk set up with a cover. The CBX 550 also had it
And we are talking early to mid 80's
 
Also,
welcome Aussie Steve and thats a cool little V-twin, does it have 2 plugs per cylinder?
happen to have any more pics of the front of the bike, I like that bikini fairing
Good luck with the build
 
Kamn said:
Also,
welcome Aussie Steve and thats a cool little V-twin, does it have 2 plugs per cylinder?
happen to have any more pics of the front of the bike, I like that bikini fairing
Good luck with the build
G'Day Kamn,
Yeah it's 2 plugs per cylinder.
here is the best I have before I pulls bits apart


 
G'Day to the rest of the blokes. thanks for reading.

yeah the CbX550 had the same strange set up.
here are the internals. Disk and caliper.



VT500Es models were produced from '83 to '88. ED and EF versions (I believe)

Perhaps someone out there can tell me? Didn't the CBX750F have very similar wheels to my bike except with dual disks? 16inch wheel though? Maybe a future upgrade 8)
 
I like that VT500E model 8) a much better sight than the VT500C Shadow models we got over here;the 500 Shadow was too 'upright' a small bike for my taste.
 
The general rule when I kicked this off was that I would try to do everything by myself. Following this ethos … try. fail. learn. retry. perhaps fail ?!?… finally try again until succeeding.

So let me continue this thread with the bike frame:
Pic with the bike partially disassembled , and for me the profile cried out scrambler. (Tracker for some?)



Customary rear hoop




Filled the rear end to stop shit hitting the underside of the seat - I did this because I only have a mini fender welded onto the rear hoop (Covered in tape in the pick in the pic.)
Don’t worry if you have concerns about the painting. I did this to clean up the frame, it’s not a final finish. When I am happy where the bike sits, I plan to pull it apart to powder coat.



I bought some used Hagon progressive shocks, supposedly from a SR500. I have read on the net, that they are decent value for money. Comments on that?
This leads me to my first genuine question that I would appreciate someone’s advice. After covering the end of the bike (hoop section) and installing the new used shocks, I have 12cm (4.7 inches) from top of the tyre to seat pan. Have I made a major cock up here? Is that enough room?
Also, I would like to do add some progressive springs in the forks. (When cash suddenly appears in my wallet)



In case anyone is heading to Aus in the near future:

Thanks gents!
 
About time I post some more stuff in this thread.
As I have read this countless times on DTT.. Get a frigging Manufacturer manual. As soon as I got my bike I bought a Clymers, bit after raiding the advice on herer I also downloaded an original Honda pdf that I found floating around on a forum somewhere.

Although at times I found the details in the manual a little to vague for a guy that hadn’t done this type of shite before, so I did a fair amount of research on Youtube.

Here are few vids that I found quite helpful to get my head around things:

I’ll update this section as I see more useful vids or remember ‘em.

- Rebuild Brake Master Cylinder
https://www.youtube.com/watch?v=6YSldW85ioI&index=15&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8

- Valve clearance Adjustment
https://www.youtube.com/watch?v=xlx9xu22mLM

- Free seized brake caliper and instal new seals (without compressor or grease gun)
https://www.youtube.com/watch?v=rHvIA_--BAs&index=3&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8

- Service and rebuild front forks
https://www.youtube.com/watch?v=vrmYJgcGX30&index=11&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8

- Clean and Rebuild carbs
https://www.youtube.com/watch?v=Yi4Z8wTOUM8 (check it out! Cool informative laid back Aussie build here)
https://www.youtube.com/watch?v=exa467_eoXw&list=PL0557182BD945AE00

- Removing and flushing a motorcycle radiator
https://www.youtube.com/watch?v=MKuzSw9L82Q&index=44&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8
https://www.youtube.com/watch?v=GFb01PKM-cE&index=50&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8

- Radiator Fan Service
https://www.youtube.com/watch?v=MAvbOGxdxaQ&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8&index=53

- Thermostat Fan Switch Test
https://www.youtube.com/watch?v=lkwJoLBGr9Q&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8&index=55

- Compound Curve Decal Application on a tank
https://www.youtube.com/watch?v=ufdktEdfNnE&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8&index=22

- Steering Head Bearings
https://www.youtube.com/watch?v=_Ozfh93CvBs&index=9&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8

- Starter Issues
https://www.youtube.com/watch?v=DYec1yFX3YI&index=7&list=PLyLD4YZV54XKKxA2teAyt54lC8O87QvO6
https://www.youtube.com/watch?v=9EHQJDhxZc0&index=46&list=PLNKmRBCzQKbOR5HDv75PsfFGexulRhTe8
https://www.youtube.com/watch?v=9HgyhUjVWY8

- Cylinder compression test and leak down test
https://www.youtube.com/watch?v=tiza8Zdnvik

I heard this call the other day.. gold! 8)
Well slap a cow's cunt on your head and hope that some bull comes along and fucks some sense into you! ;D
 
I got pretty successful results with electrolysis, the method was able to grab quite a lot of rubbish rust sitting in the tank.. well that was until the battery charger blew. ;)
After I flushed the tank, I lined it with some epoxy that I could source.

 
and this was how the bike was sitting after 4 months of action. Slow progress unfortunately.
Although I was happy how it was looking, the tkc80 tires really set it off!

 
Exhaust:
I decided on replacing the stoke mufflers and deleted the exhaust chamber underneath the bike.
Yet, again it was a task I had never undertaken before.
I bought a set of used mufflers, I have no idea what they were from?

Nothing complicated about it.. No pipe bender available so I just cut slots to create the angle I desired, then welded it up!
Ignore the bird shit welds. Everything ended up being covered in wrap ;D









 
It was about this time I took an angle grinder to my wrist..not one of my better moments.
But a few stitches never killed a dude.. I think I freaked out the young Polish doctor when I was in emergency. There I was taking photos, whilst he was cleaning up the wound ;)

 
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