1978 Honda CX500 Cafe Build

downtown809 said:
if you are contemplating on a build of your own with one of these bikes make sure the donor bike has had a triple bypass as these are required past 25K miles and are expensive. You are looking for 3 punch marks on the engine by the vin number.
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Those 3 punch marks on the engine don't indicate a triple bypass, it just means the engine has had it's recall for the timing chain mod. The bolt that holds the guide in had a ruber coating and this caused it to back out, they replaced it with a non rubber coated bolt, this was on the '78 only so later models wont have the punch marks as they didn't need the recall.

A triple bypass is the replacement of the oilseal/mechanical seal, cam chain and stator. There's no defined time when it needs doing but since it's an engine out job it's not uncommon to do all 3 at once when doing a rebuild and knowing you have a good solid runner after it. The main cost is the timing chain and stator.

Cheers
Steve
 
Brake fluid, what to do.. Everything painted up nice but time to bleed the brakes. Fill the reservoir with fluid only to put the lid on and out comes the extra fluid to ruin the paint on the master cylinder, front fender and wheel, blah. I guess this is when powder coating comes in handy?
 
MotorbikeBruno said:
I bet you won't make that mistake again though.
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This is one to learn very early on. I cover stuff with terry cloth towels before I start, and as a rule, the tank will not even be on the bike. Most important is to just be neat and careful, and not overfill the master cylinder. A single drop of brake fluid anywhere on a freshly built bike is essentially a disaster. That stuff is motorcycle kryptonite.

I don't even install the painted parts until everything else is done. Tank and front fender go on LAST. Nothing will piss you off faster than a wrench or screwdriver slipping out of your hand and dinging up that brand new paint job. The temptation to put pretty parts onto the bike is very strong, because you want the reward of seeing those parts on the bike ASAP. Those parts need to be a safe distance from the work zone until the bike is finished.
 
Thanks guys, headed downstairs to get some word done on mounting the seat and battery box, stay tuned.
 
Made up a piece of aluminum to mount the rectifier and Starter solenoid. I am limited on space under the seat so they are mounted on the underside of the bracket.
 

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Sick bike , I just bought a running 82 cx 500. I was wondering where u got the seat from? Or if u made it, if u made it do u have pic of the process?
 
link of the seat, he will make it in any color he has in stock. http://www.ebay.com/itm/Honda-CX500-Standard-Deluxe-modified-seat-pan-/181062120675?_trksid=p5197.m2280&_trkparms=aid%3D222002%26algo%3DSIC.FIT%26ao%3D1%26asc%3D14133%26meid%3D5603734616509103830%26pid%3D100068%26prg%3D1085%26rk%3D3%26sd%3D200893169568%26%26clkid%3D5603737738098504805&_qi=RTM1303754
 
Working on the battery box today. I bought some sheet aluminum and cut it to size with the cut off saw. Had a buddy tig weld it together and it fits the notch under the engine just fine. Now back to the shop to get the angles welded on.
 

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