- Joined
- Jan 18, 2008
- Messages
- 753
- Reaction score
- 6
- First Name
- Mike
- Last Name
- Farris
Update:
Stupid photobucket has decided to not allow photo hosting of links from other sites, therefore almost all photo links in this thread are broken. It's a shame because there are lots of documented mods covered here.
If you want to see the photos, you will now have to go directly to photobucket site and endure all the pop up adds. I'm sorry for this.
Here is a link to the folder with all the cx500 photos:
http://s524.photobucket.com/user/EnduroRdr_photos/library/cx500-DS-Project
For those visiting this thread for the first time, I can use Tapatalk to post a pic of the bike (since photobucket no longer allows direct links) to show my bike in before and after shots. Too many photos to repost them all, you will need to go to link above to see the rest:
Before shot - when I purchased the CX500 in July 30 2009:
Then about 7 years later.
Here is 2016 CX500 and probably 15k miles into project:
The photo link will be chronologically backwards (newest photos first over the last 7 years) - enjoy!
End edit:
Start of original post:
...............................................
Ok I got all inspired by this thread:
http://www.twtex.com/forums/showthread.php?t=41070
After looking around I picked up a CX500 on the cheap and got started:
So it's really all your fault - all the TWT posters that got me looking for a new project -
Actually the inspiration was this bike:
Having had many BMWs in the past I was wanting to build an airhead d/s bike. But finding a reasonably priced doner seemed out of reach these days so then got all worked up over a cx500 instead:
Ok enough chit chat here is the build story:
I know how most of us like pics so I'll try to use a lot of pictures and try to not get to wordy
Got this bike seen here day one: The starting point - a $300 bike off craigs list - all I cared was it had clean title & it started (although it ran ruff) it didn't knock, so I knew I had a good solid base to work from.
And here it is after over a year:
But that is getting ahead of myself - first I will take you through the build that got us to that point.
Well got it home then it sat for 6 months while other priorities got done and started the conversion in Jan 2010, here stripping it down to see just what the heck I ended up with:
After some coxing and a over night charge on the battery I got it started. Took it around the block and it ran like crap: Better take the carbs apart and clean them out, sure enough the low speed jets were plugged with varnish. But the real problem was the previous monkey had taken the carbs apart and put the right side butterfly in backwards - 180" out and it didn't seat right. I had some spare carbs in boxes for parts that's why you will see extra carb bodies in the pic. Sometimes saving junk pays off - :
Well well while in there I also found one side was missing the important rubber stopper for the second jet. All my spare parts were from other years and for some reason Honda made these 1982 carbs with bigger holes so the only plug that fit was the one - I need 2! Since I didn't have it but have machine tools I can make it, using some aluminum and a generic o-ring kit:
Making the plugs:
Comparing the one rubber plug to the replacements after completion:
Another view for those of you that never seen the inside of a Honda CV carb.
And here installed to show where they were supposed to go:
Got rid of that 16" rear wheel and found a 18" off fleabay then mounted a Dunlop D606:
Next the plan was to swap out the wimpy front forks with some cr USD forks I had in the shop, I got them basically for free as I bought a blown up cr for parts thinking I would use the front end on my XR400 and after selling off the rest of the bike got all my money back and still had the front end left.
Well that xr swap never happened so now it goes on the cx500, but first I need to do something with the rear end. Mounted these Yamaha tt500 shocks, raised it about 2 inches:
The cx was bought without any mufflers, but that's ok I wanted something lighter anyway so then I had some 1.5" pipe bent at local muffler shop then welded it all together to mount this supertrapp:
The underside after removing that heavy cross over thing that was about 20 pounds. Now it is just light pipe going 2 into 1 using an XR650L supertrapp.
Now it's time to move to the front end. Pulled it all off and found the bearings were different (well I didn't think I would be that lucky anyway)
Well my luck was even worse when I visited local bearing shop and found there was no match to fit the cr stem to the cx frame:
CX500 ball bearing race:
CR Roller bearing race:
Ok so now regroup. Well my options were do some serious steering stem work or take 2.5mm off the cr bearing races. I got a machine shop so what the **** go for it. I figured the bearing race thing would be easier. Took me about 8 hours but I finally got the races perfect (and straight too - )
Had to make a jig to hold the bearing races true:
Then took all day grinding them slowly - better to be safe check twice cut once!:
Comparing the two cx ball bearing to cr roller:
Comparing the stems (triple trees), quite a bit bigger but not too far off on height:
Although the cx forks are about 4 inches shorter. After raising the rear 2 inches on the shocks and about another 1 inches on tires (the Dunlop D606 on 18" rim was about 2" taller when compared to the 16" wheel & tire so 1/2 that dimension) adding all that up gave me about a 3 inch lift in rear. means Id have to slide the forks up an inch, and then there is the difference of 2 inches taller 21" front wheel than the 19" stock. So now I got to slide the forks up 2 inches to get somewhere close to same rake:
So now I got the bearings to fit the frame but the stem is about 1/2" longer and the dust seal from the cx will not fit the cr triple. Ok I can solve that in one part, making a new dust seal and spacer for the top of the cr stem to cx frame:
Here is it mounted, nice tight fit to keep dirt out and grease in:
Ok here is first fitting of new front end: Note still working out the seat issues will address that later:
Decided to get rid of all that weight from the instruments on the handlebars.
Loosing the speedo & tachometer saves several pounds. I elected to install a TrailTech Vapor instead along with the dash board for the idiot lights (I kinda like having a neutral light and oil pressure warning light - ) :
The back side of Vapor but still sorting out the wiring in this shot:
Ok now that I'm using the Vapor and removing that big *** heavy tachometer I need to get rid of the tach cable too. (that saves another lb. or so) But I didn't want a hole in the motor to collect dirt. time to make a plug to replace the cable in the motor using a small piece of 5/8 aluminum round stock:
Now finished part:
And part installed:
Installing the Vapor its time to hookup the water temperature sensor. Since I had a CR front wheel I ordered the kit for the cr but when I tried to install the water sensor into the cx water hoses I found it was quite a bit smaller than the hoses were.:
Well next option was to just use the sensor (without the piping tee) and put it in the same location as the cx sensor. Easy right? Well again I'm not that lucky. the thread on the stock cx sensor was quite a bit larger than the Trailtech kit sensor.
Original CX sensor:
Ok so maybe I can use a bushing? Removed the sensor and compare it to all my fittings and it is not anything standard (looks like a 3/8 pipe thread but on close inspection it is not) Well I did have a spare that was same as the CX so maybe I can use it as a nipple/bushing for the TrailTech sensor?
Drilling out the large sensor:
Comparing finished product to spare:
And now new sensor installed: (yea that's some glycol residue that dripped out on my motor - )
Ok now I got the front end finished, installed some handlebar resets (set back the bar mount to allow me to raise the forks as much as needed)
Here with new Parelli m21 front tire mounted:
But now the problem is a seat! Here I am welcoming suggestions.
In this shot I tried to fit a early 70's Husky seat but the base is too straight to fit the swooping contour of the cx frame:
And here is the stock seat which I hate the protruding passenger section. It is very comfortable though. I could sit in this seat all day and not get monkey-butt like I get on the xr400 seat but dang its ugly! Maybe I can cut off the rear section some?
Here is another guys answer to the seat delema, he used a early 80's Suzuki RM seat and It looks a lot better than the stocker and even fits the frame contour fairly well: I really like the look here - comments?
OK so now I've posted quite a bit and am up to date!
Next after I work out the seat or any other items that may require frame altering or welding then I have to strip it all down for paint on tank and side covers and power coat frame.
I welcome your comments and suggestions -
.
Stupid photobucket has decided to not allow photo hosting of links from other sites, therefore almost all photo links in this thread are broken. It's a shame because there are lots of documented mods covered here.
If you want to see the photos, you will now have to go directly to photobucket site and endure all the pop up adds. I'm sorry for this.
Here is a link to the folder with all the cx500 photos:
http://s524.photobucket.com/user/EnduroRdr_photos/library/cx500-DS-Project
For those visiting this thread for the first time, I can use Tapatalk to post a pic of the bike (since photobucket no longer allows direct links) to show my bike in before and after shots. Too many photos to repost them all, you will need to go to link above to see the rest:
Before shot - when I purchased the CX500 in July 30 2009:
Then about 7 years later.
Here is 2016 CX500 and probably 15k miles into project:
The photo link will be chronologically backwards (newest photos first over the last 7 years) - enjoy!
End edit:
Start of original post:
...............................................
Ok I got all inspired by this thread:
http://www.twtex.com/forums/showthread.php?t=41070
After looking around I picked up a CX500 on the cheap and got started:
So it's really all your fault - all the TWT posters that got me looking for a new project -
Actually the inspiration was this bike:
Having had many BMWs in the past I was wanting to build an airhead d/s bike. But finding a reasonably priced doner seemed out of reach these days so then got all worked up over a cx500 instead:
Ok enough chit chat here is the build story:
I know how most of us like pics so I'll try to use a lot of pictures and try to not get to wordy
Got this bike seen here day one: The starting point - a $300 bike off craigs list - all I cared was it had clean title & it started (although it ran ruff) it didn't knock, so I knew I had a good solid base to work from.
And here it is after over a year:
But that is getting ahead of myself - first I will take you through the build that got us to that point.
Well got it home then it sat for 6 months while other priorities got done and started the conversion in Jan 2010, here stripping it down to see just what the heck I ended up with:
After some coxing and a over night charge on the battery I got it started. Took it around the block and it ran like crap: Better take the carbs apart and clean them out, sure enough the low speed jets were plugged with varnish. But the real problem was the previous monkey had taken the carbs apart and put the right side butterfly in backwards - 180" out and it didn't seat right. I had some spare carbs in boxes for parts that's why you will see extra carb bodies in the pic. Sometimes saving junk pays off - :
Well well while in there I also found one side was missing the important rubber stopper for the second jet. All my spare parts were from other years and for some reason Honda made these 1982 carbs with bigger holes so the only plug that fit was the one - I need 2! Since I didn't have it but have machine tools I can make it, using some aluminum and a generic o-ring kit:
Making the plugs:
Comparing the one rubber plug to the replacements after completion:
Another view for those of you that never seen the inside of a Honda CV carb.
And here installed to show where they were supposed to go:
Got rid of that 16" rear wheel and found a 18" off fleabay then mounted a Dunlop D606:
Next the plan was to swap out the wimpy front forks with some cr USD forks I had in the shop, I got them basically for free as I bought a blown up cr for parts thinking I would use the front end on my XR400 and after selling off the rest of the bike got all my money back and still had the front end left.
Well that xr swap never happened so now it goes on the cx500, but first I need to do something with the rear end. Mounted these Yamaha tt500 shocks, raised it about 2 inches:
The cx was bought without any mufflers, but that's ok I wanted something lighter anyway so then I had some 1.5" pipe bent at local muffler shop then welded it all together to mount this supertrapp:
The underside after removing that heavy cross over thing that was about 20 pounds. Now it is just light pipe going 2 into 1 using an XR650L supertrapp.
Now it's time to move to the front end. Pulled it all off and found the bearings were different (well I didn't think I would be that lucky anyway)
Well my luck was even worse when I visited local bearing shop and found there was no match to fit the cr stem to the cx frame:
CX500 ball bearing race:
CR Roller bearing race:
Ok so now regroup. Well my options were do some serious steering stem work or take 2.5mm off the cr bearing races. I got a machine shop so what the **** go for it. I figured the bearing race thing would be easier. Took me about 8 hours but I finally got the races perfect (and straight too - )
Had to make a jig to hold the bearing races true:
Then took all day grinding them slowly - better to be safe check twice cut once!:
Comparing the two cx ball bearing to cr roller:
Comparing the stems (triple trees), quite a bit bigger but not too far off on height:
Although the cx forks are about 4 inches shorter. After raising the rear 2 inches on the shocks and about another 1 inches on tires (the Dunlop D606 on 18" rim was about 2" taller when compared to the 16" wheel & tire so 1/2 that dimension) adding all that up gave me about a 3 inch lift in rear. means Id have to slide the forks up an inch, and then there is the difference of 2 inches taller 21" front wheel than the 19" stock. So now I got to slide the forks up 2 inches to get somewhere close to same rake:
So now I got the bearings to fit the frame but the stem is about 1/2" longer and the dust seal from the cx will not fit the cr triple. Ok I can solve that in one part, making a new dust seal and spacer for the top of the cr stem to cx frame:
Here is it mounted, nice tight fit to keep dirt out and grease in:
Ok here is first fitting of new front end: Note still working out the seat issues will address that later:
Decided to get rid of all that weight from the instruments on the handlebars.
Loosing the speedo & tachometer saves several pounds. I elected to install a TrailTech Vapor instead along with the dash board for the idiot lights (I kinda like having a neutral light and oil pressure warning light - ) :
The back side of Vapor but still sorting out the wiring in this shot:
Ok now that I'm using the Vapor and removing that big *** heavy tachometer I need to get rid of the tach cable too. (that saves another lb. or so) But I didn't want a hole in the motor to collect dirt. time to make a plug to replace the cable in the motor using a small piece of 5/8 aluminum round stock:
Now finished part:
And part installed:
Installing the Vapor its time to hookup the water temperature sensor. Since I had a CR front wheel I ordered the kit for the cr but when I tried to install the water sensor into the cx water hoses I found it was quite a bit smaller than the hoses were.:
Well next option was to just use the sensor (without the piping tee) and put it in the same location as the cx sensor. Easy right? Well again I'm not that lucky. the thread on the stock cx sensor was quite a bit larger than the Trailtech kit sensor.
Original CX sensor:
Ok so maybe I can use a bushing? Removed the sensor and compare it to all my fittings and it is not anything standard (looks like a 3/8 pipe thread but on close inspection it is not) Well I did have a spare that was same as the CX so maybe I can use it as a nipple/bushing for the TrailTech sensor?
Drilling out the large sensor:
Comparing finished product to spare:
And now new sensor installed: (yea that's some glycol residue that dripped out on my motor - )
Ok now I got the front end finished, installed some handlebar resets (set back the bar mount to allow me to raise the forks as much as needed)
Here with new Parelli m21 front tire mounted:
But now the problem is a seat! Here I am welcoming suggestions.
In this shot I tried to fit a early 70's Husky seat but the base is too straight to fit the swooping contour of the cx frame:
And here is the stock seat which I hate the protruding passenger section. It is very comfortable though. I could sit in this seat all day and not get monkey-butt like I get on the xr400 seat but dang its ugly! Maybe I can cut off the rear section some?
Here is another guys answer to the seat delema, he used a early 80's Suzuki RM seat and It looks a lot better than the stocker and even fits the frame contour fairly well: I really like the look here - comments?
OK so now I've posted quite a bit and am up to date!
Next after I work out the seat or any other items that may require frame altering or welding then I have to strip it all down for paint on tank and side covers and power coat frame.
I welcome your comments and suggestions -
.
Last edited: