Honda CX500 & GL500 Forum

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01-24-2009, 9:52 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 CX500 caffeination phase two 99% Done! Ok guys, now that I'm back from the middle east its time for me to start phase two of the little CX cafe that could. Got a lot to do! Stuff I've completed colored in Red and stuff that has been nixed/done differently in light grey -Chop more of the back of the frame off (and any unnecessary brackets) -Weld brackets to end of frame for the attachment of a “back plate” to seal off bottom back of cowl -Weld electronics pan to frame -Weld new flat seat rails to top of frame for seat -Weld up a seat mounting point at the back -Weld up mounts for rear sets -Repaint frame (probably going with “Champagne”) -Create new rear fender (that sits close to the wheel and mounts near the center/bottom of the frame... similar to the red framed ducati from the Davida ad.) -Nickel Plate Fuel Tank -Line Fuel Tank -Create a new seat pan -New Taillight lens -Repaint motor -Replace fork seals -Strip paint off wheels (TBD whether to repaint or to polish) -Bob fender -Repaint brake caliper -Replace front brake pad -New master cylinder -Steel brake line -Clip ons -Bar end blinkers -New clutch and throttle cables -Brown grips -Complete rewire. move everything under seat (halfway there) -Relocate battery to bottom of electronics pan -Digital speedo/tach -Figure out how to connect rear sets (CX clutch lever is at the back of the motor, not the side) -Either get a shorter mirror... and/or put a mirror on the bottom of the front fork. (anyone else see this done? its looks pretty cool... don't know how functional it is tho) I know it seems like a lot... Buuut I only need two classes to graduate this semester so I should have enough time to finish it for May. Now the only problem is gathering up all the parts i need so it doesn't cost a small fortune. My biggest concern right now is how to get the color i want for the frame. i want it to be champagne... i.e. silvery with a hint of bronzish-gold. the problem I'm running into is that they don't make any heavy duty spay paints in that color (and powder coating is going to put me over budget). I think what i might do is strip the frame, coat it with self etching primer, hit it with several coats of one of the duplicolor champagnes, and then put a good amount of heavy duty clear coat on it. (I have one thats meant to be used when painting wheels... its not duplicolor though... would this have any adverse effect on the color layer?) Also, I'm gonna be getting a sealed battery. Now its recommended that my bike take a 12v 14ah battery. These things are huge! would it be possible to get one with less amps per hour (and so smaller dimensions) and have the bike run ok? (maybe like 8ah) Phase Zero: Phase One: because I'm too poor to buy a 'Guzzi    Report

01-24-2009, 10:26 AM PWG in Lowgap NC Joined on 01-07-2008 Minutes from the Blue Ridge Parkway Posts 2,381 Re: CX500 caffeination phase two Have you considered "tinning" the tank? It's what they used to do to those big Milk cans back in the days before farm to farm tankers. It would be a lot less expensive and a do it yourself project. 06 Suzuki S50 daily ride CX500c Honda Magna BC age 72    Report

01-24-2009, 10:29 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two i can have the tank nickel plated for $110 which i dont think is too bad... got any links on tinning how-tos? because I'm too poor to buy a 'Guzzi    Report

01-24-2009, 10:45 AM brandondubya Joined on 01-18-2009 utah Posts 55 Re: CX500 caffeination phase two how is your seat sitting on there right now? is the fiberglass pan just over the dip in the frame or is something rienforcing it? 81 cx500 custom cafe in the works    Report

01-24-2009, 10:51 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two i made a steel seatpan for it.  ill get pics when i dismantle the bike because I'm too poor to buy a 'Guzzi    Report

01-24-2009, 1:46 PM brandondubya Joined on 01-18-2009 utah Posts 55 Re: CX500 caffeination phase two that would be awesome and really helpfull. I think i've decided how i am going to mount mine but it would like to see someone elses 81 cx500 custom cafe in the works    Report

01-24-2009, 4:24 PM Blindstitch2002 Joined on 05-16-2007 Greenfield Wisconsin Posts 5,000 Re: CX500 caffeination phase two So besides the engine are there any other parts that your thinking of keeping. Do you have pods on your bike already. If so you could just use the airbox area for your battery. Keep us posted with pictures. 1978 Honda Cx500 Maggot 1979 Honda Cx500 Custom 1980 Cx500 Deluxe Buy HTTA Items Quick Reference Info    Report

01-24-2009, 7:26 PM BearCX Joined on 03-11-2008 Roseworthy, Sth Aust Posts 525 Re: CX500 caffeination phase two Not sure about running an undersize battery. I know my 500 wont start without a Fully charged 14Ah. Even if it's a little flat, she wont fire up. Should be OK once she's started. If you're still in control...You're not going fast enough.    Report

01-24-2009, 10:59 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two  Blindstitch2002 wrote: So besides the engine are there any other parts that your thinking of keeping. Do you have pods on your bike already. If so you could just use the airbox area for your battery. Keep us posted with pictures. I do have pods.  no matter what size no leak battery i get, its gonna get bolted to the bottom of my electrical pan under the seat because I'm too poor to buy a 'Guzzi    Report

01-25-2009, 2:38 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two ok guys, got a little progress today... not as much as I wanted tho, need to figure out how to turn the heater on in the greenhouse :-/ oh, and i need to figure out how to get my jack out of the shed...  waaay too much snow :( next step is to drop the motor.  :-X  brandondubya wrote: that would be awesome and really helpfull. I think i've decided how i am going to mount mine but it would like to see someone elses heres how the frame is: and heres a side view of my seat pan: top view (yes that is velcro.  and yes that is how I temporarily mounted the seat): And a view of the pan on the seat: It should be noted that that was only a temporary solution.  the seat pan wasnt secured at the front (all it wouldve taken would have been a tounge bolted there) but it served its purpose because I'm too poor to buy a 'Guzzi    Report

01-25-2009, 9:50 PM DavidfromWisconsin Joined on 03-19-2008 Appleton, WI Posts 2,458 Re: CX500 caffeination phase two Bear, Take your starter apart and clean everything spotless. The lube the end caps and re-assemble. I'll bet that 14AH battery spins it really nice. DO NOT USE SANDPAPER!!!  DO NOT USE STEEL WOOL!!! I recommend a Scotchbrite Pad. You really won't believe what difference it makes. David From Wisconsin ... R80Dave '82 GL500I alias Candy '82 GL500I alias Candy II '00 BMW K1200LT & trailer '81 KZ440 (Wife's learning bike)    Report

01-26-2009, 1:55 AM BearCX Joined on 03-11-2008 Roseworthy, Sth Aust Posts 525 Re: CX500 caffeination phase two Appreciate the comments, Dave. Nothing wrong with my CX, I was commenting on Catacl1sm's thought of using an 8 Ah battery. The CX needs a good kick to get it to turn over. If you're still in control...You're not going fast enough.    Report

01-26-2009, 10:24 AM jfarabee Joined on 10-19-2008 Sarasota, FL Posts 344 Re: CX500 caffeination phase two Has anyone ever used those compression release spark plug caps? I see them for Harleys, and they are supposed to make it easier for your starter to turn the engine. '81 CX500 C '86 CB700SC Nighthawk    Report

01-26-2009, 10:39 AM Blindstitch2002 Joined on 05-16-2007 Greenfield Wisconsin Posts 5,000 Re: CX500 caffeination phase two I don't think it's as simple as a cap. I just did a search and maybe found the wrong thing but it involves drilling a hole in the head. http://www.hotbikeweb.com/tech/0306hb_installing_compression_releases/index.aspx 1978 Honda Cx500 Maggot 1979 Honda Cx500 Custom 1980 Cx500 Deluxe Buy HTTA Items Quick Reference Info    Report

01-26-2009, 10:47 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two ok guys... I seem to have a slight problem... my clipons came in two days ago, and when I went to drop them on, the air assist nozzle gets in the way.  I feel like crap right now, but I'll try to get pics later because I'm too poor to buy a 'Guzzi    Report

01-28-2009, 12:11 PM UnknownRoad Joined on 09-07-2008 South Carolina Posts 159 Re: CX500 caffeination phase two Along with stripping/cleaning the starter, if you're having trouble starting the bike on a fresh battery, make sure that all of your connections (battery to solenoid, solenoid to starter, battery to frame) are clean at both ends. I had no problem running my CX off my SV650 battery, which is a 12Ah battery that is a LOT smaller dimensionally than the stock CX lump, although it'll cost you about $70. CX battery- YB14L-A2 - 5.3125" x 3.5" x 6.5625" - 7.7 lbs SV battery- YT12A-BS- 6" x 3.4375" x 4.1875", 6.3 lbs. If you switch to pods, with a little fabrication it'll sit on the little "shelf" that the airbox used to sit on with room to spare... plus you can mount it laying down sideways if you want. C, if you want to just ditch the air assist, I can send you some non-air fork caps (assuming 33mm forks), $6 shipped. Various parts of: '78 and '79 CX-As, '80 CX-C, '81 CX-D, '82 GL. Goal: 2 usable bikes Current status: 0 usable bikes! AGAIN! ARRRRRRGH! I HATE CARBS! HATE HATE HATE! HATE HATE!    Report

01-29-2009, 2:58 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two thanks Unknown, but i think the '82 custom has 35mm forks (could be wrong, haven't measured myself) because I'm too poor to buy a 'Guzzi    Report

01-29-2009, 7:35 PM brandondubya Joined on 01-18-2009 utah Posts 55 Re: CX500 caffeination phase two thanks for the pics of your seat its helping me figure mine out. 81 cx500 custom cafe in the works    Report

01-30-2009, 6:07 AM cxcure Joined on 01-15-2009 CT Posts 17 Re: CX500 caffeination phase two Great thread and pics Trevor. Thank you for the reply and the pics of seat pan. I will post pics of my project when I can get to really putting some time into it. Great posts, keep them coming. -Frank 1980 Honda CX 500 C (cafe project) 2007 Triumph Scrambler    Report

01-30-2009, 2:38 PM RichNCT Joined on 03-02-2006 Connecticut, USA Posts 3,463 Re: CX500 caffeination phase two Yes, '81-82 CX500 has 35mm fork tubes. Refueling on The James Bay Road, 2009 Born to be relatively wild (for a grampa x 3) GL650I, CX650E, CX650T    Report

01-30-2009, 5:11 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two ok guys, dropped the motor today I think I may need to drill out the screws on the radiator cover.  no matter how much penetrating oil i spray on them they still wont budge, and they're so soft I'm on the verge of stripping them. Also pulled my starter today, and upon opening a whole mess of crap came out (flakes from the mineral that rubs against the main shaft I presume) Anyone have any walkthrus on a proper cleaning?  (the screws on the side are stuck fast, soaking them in oil too) because I'm too poor to buy a 'Guzzi    Report

01-30-2009, 5:51 PM Blindstitch2002 Joined on 05-16-2007 Greenfield Wisconsin Posts 5,000 Re: CX500 caffeination phase two For the radiator cover I thing you forgot about the cheapest most never used tool to have in your toolbox. Go find your self a $5 impact driver. It's the only way to get those screws out without drilling and extractors. Mine has paid for itself several times over. Enough that I bought it a little buddy. In a pinch get the right size screwdriver that fits and a hammer and strike it the same way as you would do an impact driver but it may take twice as many hits but can work. Oh when you get the screws out throw them away and pick up 8 new M6 screws. 1978 Honda Cx500 Maggot 1979 Honda Cx500 Custom 1980 Cx500 Deluxe Buy HTTA Items Quick Reference Info    Report

02-04-2009, 9:47 AM RichNCT Joined on 03-02-2006 Connecticut, USA Posts 3,463 Re: CX500 caffeination phase two Starter R&R:  You've got it apart, as long as you paid attention as to where the washers and shims came from you're on the right track.  Blow or wash with electric/contact or electric motor cleaner (aerosol can) and/or compressed air to get all the parts clean.  I wouldn't use soap & water, or gasoline/mineral spirits.  Chuck the armature in a hand held drill and spin it to polish the commutator with scotchbrite until smooth.  Clean it up again to remove any particles.  Use a tiny dab of grease or a single small drop of oil in each end bushing.  Make sure the carbon brushes are not worn to a nubbin, and reinstall then oriented correctly for the direction of rotation and angle, basically, match them against the commutator curvature.  Check that the brush springs are still springy, not melted or annealed soft from overheating.  Reassemble being careful as you guide the carbon brushed over the commutator to avoid chipping the brushes.and reinstall, expecting it to work noticeably better.  Minimal lube is needed, especially on the commutator end, so as not to contaminate the brushes/commutator.  There should be an O-ring in the starter hole on the engine.  Don't forget the ground cable that attaches under a starter mounting bolt on some models. I have done this to numerous starters and never used any new parts.  It always makes an improvement in starting vigor.  Once you've done one, it takes about 45 minutes including removal and reinstall. Refueling on The James Bay Road, 2009 Born to be relatively wild (for a grampa x 3) GL650I, CX650E, CX650T    Report

03-07-2009, 3:13 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two After a long hiatus I am back with some major progress I chopped more off the back of the frame,welded up some, bracing, seat supports, and an electronics pan, and in the pics i have just hit it with self-etching primer.  because I'm too poor to buy a 'Guzzi    Report

03-08-2009, 1:13 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two painted it today first coat: Arizona Beige second coat:  Dark Shadow Grey because I'm too poor to buy a 'Guzzi    Report

03-08-2009, 3:05 PM Jordan31 Joined on 06-12-2007 West Virginia Posts 95 Re: CX500 caffeination phase two That color really looks good.  Really makes me want to strip my bike down to the frame! http://jordango.com/cafe-racer/    Report

03-08-2009, 3:08 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two thanks, it actually looks a lot lighter when the sun hits it, almost like a pewter with a hint of gold.  im definatley diggin it... now i need to start putting the bike back together... because I'm too poor to buy a 'Guzzi    Report

03-08-2009, 3:14 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two A better pic of the final outcome because I'm too poor to buy a 'Guzzi    Report

03-08-2009, 3:14 PM stormtrooper784 Joined on 08-22-2007 Idaho Posts 332 Re: CX500 caffeination phase two Yea, thanks for making me more self concious about the ugly stock frame on my bike! Looks good, keep the pic's comming! 81' CX500D 80' CX500C parts all over the place!!!!    Report

03-13-2009, 9:48 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two shocks came in today... bitch-tits. one question though, is it ok to run the eye-mounts without the metal insert in them (using just the rubber ring instead)  because it fits without the inserts, but not with them. because I'm too poor to buy a 'Guzzi    Report

03-13-2009, 11:21 AM Thunder Joined on 12-09-2008 Indianapolis, IN Posts 66 Re: CX500 caffeination phase two Sproully75 and I both took the metal inserts out of our shorty shocks when installed, and I've ridden 100+ miles since then with no problems.  When you think about it, it's going to be metal on rubber with or with out the inserts. 1982 CX500c    Report

03-13-2009, 11:33 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two good point because I'm too poor to buy a 'Guzzi    Report

03-13-2009, 3:44 PM Blindstitch2002 Joined on 05-16-2007 Greenfield Wisconsin Posts 5,000 Re: CX500 caffeination phase two Now those are pretty crazy.  For a second there I thought that you might try mounting them as a center shock. 1978 Honda Cx500 Maggot 1979 Honda Cx500 Custom 1980 Cx500 Deluxe Buy HTTA Items Quick Reference Info    Report

03-14-2009, 5:58 PM kingston73 Joined on 04-19-2008 Bellingham, MA Posts 1,722 Re: CX500 caffeination phase two That's lookin good so far.  Those are some nice shocks, what are they?  Have you cleaned up your starter yet?  If you follow Rich's directions it'll definitely work, I had one that had sat in the rain for who know's how long and was so rusted it wouldn't spin at all.  Took it apart and put things back together and started up the bike with it for the first time today and it worked great.  1979 cx500D - mostly stock    Report

03-14-2009, 9:42 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two the shocks i got on ebay...  they were from france, and i think they are vortex or soemthing like that (just got back from the bars... a little rusty)  as for the starter....   the screws on the steel "cylinder" were frozen, even afeter several weeks of liquid wrenching them.  so i emptied out the dust and w;hatnot and ill get around to doing a complete overhaul eventually because I'm too poor to buy a 'Guzzi    Report

03-15-2009, 1:30 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two a little more progress, got the steering head in and started the rear end... hopefully i'll have the motor in by the end of the week. still have to finish stripping that rear wheel... just couldn't wait :P because I'm too poor to buy a 'Guzzi    Report

03-20-2009, 12:44 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two heres an update children! got the motor mounted more or less... just have to wrestle the drive shaft forward into coupling with the motor grrr.... tank should be done next week just have to clean up the rear wheel and get my brake sorted out because I'm too poor to buy a 'Guzzi    Report

03-20-2009, 6:35 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two by the way, does anyone know what the mounts on the radiator are made of? (the brackets that fasten it to the motor which protrude from underneath the aluminum fairing) I ask this because I finally drilled out the stuck screws and removed the fairing from the rad.  and want to strip and polish it, but need to know if theres any steel i would have to paint. because I'm too poor to buy a 'Guzzi    Report

03-22-2009, 7:56 PM Telly Joined on 07-08-2008 Cambridge, MA Posts 171 Re: CX500 caffeination phase two Good Progress! Thanks for inspiring me. I got the Parts bike stripped down to the frame thursday night, and I got some Ox-Away (Product Post Coming) which cleaned up my rusty wheels very very nicely (Next is the chrome paint) I'm calling Air-Tech this week for my Rickman Fairing and either a Ducati or Rickman seat. Meanwhile I'm putting the running bike back together to ride. Season is starting up. BTW Did you wrap the entire MAC exhaust? I had a little trouble with it, but it's on the back burner. 78' CX500 78' CX500 parts bike 83' GL650 http://transeversetwin.blogspot.com/    Report

03-22-2009, 9:06 PM Wood_Dubby Joined on 01-29-2009 West Jordan, Utah Posts 262 Re: CX500 caffeination phase two Dude, I'm just getting started putting my bike together and into running condition and now you go and make me want to pull it apart and strip and paint it! Good job on it so far- do you do your own welding, or do you have someone do the work for you? 1982 CX500 Custom (A Frankenstein of a machine).    Report

03-23-2009, 4:45 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two I do my own welding, theres a steel yard here in providence that has open sessions once or twice a week where you can go in an use the equipment because I'm too poor to buy a 'Guzzi    Report

03-23-2009, 7:27 AM Blindstitch2002 Joined on 05-16-2007 Greenfield Wisconsin Posts 5,000 Re: CX500 caffeination phase two Just curious. I see you built a better rack to hold your seat pan but why didn't you close up the area on the sides between the rack and the frame. My one pet peeve on cx cafe's is that you can see under the seat but then of course most I see someone just threw a seat across and it's floating. I do like the open season welding. Which I could find a place like that. 1978 Honda Cx500 Maggot 1979 Honda Cx500 Custom 1980 Cx500 Deluxe Buy HTTA Items Quick Reference Info    Report

03-23-2009, 7:37 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two I'm gonna make some "tabs" that will mount there to cover up the hole.  didn't want to weld anything in because I hadn't yet figured out the new wiring routs when I had made it because I'm too poor to buy a 'Guzzi    Report

03-23-2009, 7:47 AM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two  Telly wrote: Good Progress! BTW Did you wrap the entire MAC exhaust? I had a little trouble with it, but it's on the back burner. it wasn't hard, the exhaust was in two pieces, so I wrapped each one separatley.  i need to sandblast the muffler ( its probably black powdercoat, seeing as paint stripper didnt do crap to get it off and sandpaper/wire brush don't do much either).  gona paint it satin silver here's the radiator with a fresh coat of paint, and I'm gonna polish the copper parts (also you can see the start of my rearsets in one of the pics) because I'm too poor to buy a 'Guzzi    Report

03-23-2009, 6:39 PM Telly Joined on 07-08-2008 Cambridge, MA Posts 171 Re: CX500 caffeination phase two  CaTacL1sm wrote: I do my own welding, theres a steel yard here in providence that has open sessions once or twice a week where you can go in an use the equipment What's the name of the place? 78' CX500 78' CX500 parts bike 83' GL650 http://transeversetwin.blogspot.com/    Report

03-23-2009, 6:50 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two its called The Steel Yard The Steel Yard they do open studios on friday nights from 6:30 to 9:30, and it costs 20 bucks.  may 1st they should be adding sunday nights to the lineup because I'm too poor to buy a 'Guzzi    Report

03-30-2009, 11:50 AM need4steed Joined on 11-06-2008 Joliet IL Posts 659 Re: CX500 caffeination phase two I have to know where did you get those sweet ass shocks and how much were they?  I have to have those.... What dont kill you makes you more strong...metallica 1980 CX500 (sold) 1982 GL500 (cafe) AKA black bomber (473 Miles since finished build) 1980 xs850 yamaha (sold) 1979 CX500 (Track Bike) 72 cl350 (cafe project #2) AKA Ol Goat    Report

03-30-2009, 4:34 PM CaTacL1sm Joined on 05-02-2008 Rhode Island Posts 583 Re: CX500 caffeination phase two ebay, search for cafe gas shocks or something like that. because I'm too poor to buy a 'Guzzi    Report

03-30-2009, 7:17 PM Reg in Bristol Joined on 03-11-2006 Bristol UK Posts 782 Re: CX500 caffeination phase two  CaTacL1sm   I must to admit to zooming through the details, but think the larger version of the avatar pics a classic !! The 'Mongrel' is on the road 78 frame, ZAB gubbins, 82 'TI' motor, Suzuki clocks, MZ screen and gaiters, Kawasaki master cylinder, BMW horns DIY wiring and all thrown together with a fanatical inattention to detail :-)    Report

04-02-2009, 11:20 PM featherw09 Joined on 04-01-2009 Upton MA Posts 5 Re: CX500 caffeination phase two Great looking bike! And we live very close.... -Will- 1984 Porsche 944 - Auto-x car 1995 Jeep Cherokee - 4.5in lift with 31's 1978 Honda CX500 - A Gem, needs some polishing and some "cafination"    Report

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