::: PROJECT : Honda CX650 Café Racer - Made in Vietnam

[VietHorse]

Hi All,
Getting around internet and decided that I gotta buy a Honda CX to modify it to be a cafe racer bike.
There are couple of things I love from the Honda CX:
1. Good looking engine block.
2. Drive shaft.
4. Stable and smooth, as it 's a Honda.

Finding a good old CX in Vietnam is not an easy job. I 've seen one or two GL/CX400 in Hochiminh City, never seen a single CX650.
Well, I gotta have one, CX650.
That why I decided to buy a CX650 from California and ship to Vietnam.
Paid the seller Feb2012. Got the bike in my hands Aug2012! Damn slow US boat. Hehe....

First, I have to say that the modification is not done by myself as I don't have a big enough workshop. A motorcycle workshop helps me to do the physical works.

I have put up some questions in here http://www.dotheton.com/forum/index.php?topic=34168.0, however nothing much I 've got.
Well, not an issue. I still can start on my own.

This would be not a everyday update thread, so, let's take it easy by starting with a Vietnamese coffee, I'll be right back:

 

[VietHorse]

Now, let's see how 's the bike...

This photo was taken by the seller in Feb 2012:

Due to some unforeseen reasons, the bike was delivered to me in Ho Chi Minh City in July 2012. No problem. I am a super patient guy.
First met the bike, let's take a round view:

10xxx miles on the clock:

I have ridden the bike for about 5km and feel really great. After some months but just two three time press the Ignition button, it starts.
Really smooth and powerful bike. Much better than what I though.

During the waiting time to the boat to arrive, I have also bought a set of front forks from a US friend in Maryland:

Right, by air is faster by boat! The upside down front forks arrive much earlier than the bike.

I have also been walking around the forums to find the ideas for my project.
Found a very good thread in ADV forum with lots of very good advices from the member named Sparkymoto.

I have put up the bike and my ideas to see how the thing would look like afterward:

Options and options.... create... edit.... delete... create....

 

[VietHorse]

A quick visit and discussion with the shop in the morning.

Weather was so good for anything related to motorcycle:

First time ever I can use my camera for some close-up look to my bike - who was born in 1983:

She has not so small heart:

Her name:

5 gears:

 

[VietHorse]

Put up the front end with inverted suspensions from Maryland friend:

Will see if I can utilize all of them, including two front brakes (instead of single disc from original CX650):

They have do some modification so that the front fork can fit with the CX frame:

Front forks look fine, but the front wheel seems small:

Take an old rear monoshock for a sample - looks okay huh?

 

[VietHorse]

At the shop for around 2hrs discussing on how to make the dual front discs instead of original single disc.
After two days, they have completed the mounting with perfect air-gap from the wheel to both front forks, and also the two break calipers.

Right disc:

Left disc:

There are two shim plates have been inserted into both side of the "rim base" (well, I am not sure if I am using incorrect word!!??).

Because of the differences between two sides of the rim, so two plates have difference thickness. That was a difficult part for getting a correct measurement. Otherwise, the two discs could not fit with the two break calipers.

We used long bolts to mount the break disc and the shim plate to the "rim base".

So, here is how the front end looks like:

The wheel looks bigger than with the single disc, right??

 

[VietHorse]

This rearshock looks a bit old:

So that why I bought a Ducati 1198 OEM monoshock to replace - this monoshock is almost new, just on the bike for some hundred miles:

This is how I make the trial fit:

Side view:

We will make a support from the bottom frame, just about 2-3 inch height. All the rear frame will be chopped off:

Overview of the rear shock design would be like this:

I may need a little frame (diagonal brace) to support the rear seat. That's not an issue, as soon as I leave a room for the air filters.

 

[VietHorse]

I was busy with riding in the US and somewhere else so the progress suck.
Not much update after some months.
......................

Mocked up the rear monoshock (from Ducati 1198) to my CX:

Well, got some issues here. The shock a bit long; its reservoir cylinder is fixed and it could not be turned the other way round to the the horizontal position. So... that's the only way and the best way to fix the shock. That's how we fix the shock to test the shock traveling.
Got the bike straight, held the rear frame and pushed it hard, I can notice the gap (distance) from the bottom of monoshock to the rear tire almost unchanged, just some mm variation,

After fixing the position for two ends of the shock, we will make a sketch for the shock support frame, there would be some options to consider.
The whole rear frame will be chopped off. A new frame - looks like the CBR rear frame is my choice to make.

In other hand, the 1mm steel plate to make the front mud guard:

Gas tank removed and the new tank will be built very soon:

 

[VietHorse]

Following with previous posts, bike leveling almost done, front forks already fixed, rear monoshock also fitted with some dummy braces and plates.
Last week, they was struggling with the gas tank. It 's quite a hard job due to my difficult requirement.
However, today, they have done almost 2/3 of the tank job:

Right side view:

Left side view:

And the tank bottom would be done by next couples of day, then the tank cap and nozzle:

Front mud guard has been done:

Chopped of the rear frame to make a new rear frame - idea of a sport bike rear frame:

Those two diagonal braces toward the rear will be chopped off:

I have a try to get the right place of foot pegs, gear and brake pedals:

The gas tank supposed to be slopped to the front a bit more:

That's it for the bike for now. Next two weeks would be very productive weeks for the bike...

 

[Rich Ard]

Great start - look forward to watching your progress!

 

[VietHorse]

Great start - look forward to watching your progress!

Thank you very much, the first comment on my build thread. And very few of the reply on my questions. ;D

 

[Das1slickninja]

Awesome project you've got there!

sub'd

 

[VietHorse]

Awesome project you've got there!

sub'd

Thanks you. Will get you posted

 

[VietHorse]

Struggling with design the headlight set up. Mine and others:

Hey, let me borrow the headlight for a while:

Hmm, mine looks suck!!

 

[SONICJK]

This is looking good man!

 

[Seaglider]

I was looking at buying one of those up here in Canada a few years back. When my brother and I get done the H1 maybe that'll be the next project. Yours is looking very good....love the inverted forks! I personally like this bike with a small fairing on it....but the street fighter look is great too!
Have fun ;D

 

[slots]

Hey, I remember you from the CX500/GL500 forum. Nice to see that you've been making some progress. Will follow your build.

 

[deepwaterimports]

yeh kewl much better lol looking good man

 

[VietHorse]

This is looking good man!

yeh kewl much better lol looking good man

Thank you Sirs. Still long way ahead.

 

[VietHorse]

I was looking at buying one of those up here in Canada a few years back. When my brother and I get done the H1 maybe that'll be the next project. Yours is looking very good....love the inverted forks! I personally like this bike with a small fairing on it....but the street fighter look is great too!
Have fun ;D

The inverted forks make the bike looks stronger at front. I was lucky that the fork and the triple clamps could fit with the original front wheel.

 

[VietHorse]

Hey, I remember you from the CX500/GL500 forum. Nice to see that you've been making some progress. Will follow your build.

Thanks Dude.
CX500 forum is great as well as it's members. They give me lots of recommendations and ideas. And I also got the plug cap there, which I was looking here on DTT and none has it for sale.