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Discussion Starter #1
Good Afternoon CX500 forum,

I figured it was about time I start a build thread for my GL500 cafe project, I wanted to do this for a couple reasons, firstly because I would like to provide help to anyone who may be struggling with the same issues I did/still am, secondly it would be great to get some feedback on my project, things I could do better ect. and finally its a great motivator for me to finish and provide some inspiration to others.

So fist ill provide some back story that has lead me to the place I am at now and then ill shire my future plans.

I first got the bike in November of 2015, I got it with intention of doing a cafe conversion, I was not really a bike guy before that but I realized there it a lot more potential (at least in my mind) to personalize a bike under tight budget constraints in comparison to modding a car. At that time I lived with some roommates at university and didn't have a garage or really any space to work on my bike so i could only work on my bike in the back yard when there was no snow and it wasn't cold outside, I also had absolutely no mechanical experience prior to this. (why i call it back yard spanner spinner)

Up to the end of summer 2016 I had done a decent amount of things to my bike which i will list off:

1. Full disassembly
2. Removed all frame tabs and cut the back of the bike off
3. Got a rear hoop welded on the back
4. Built a seat pan for the battery and electronics
5. Converted the gas tank to one from a cx500 deluxe which required the front pegs (not foot pegs) to be moved forward slightly
6. Reduce the size of the rear fender
7. Powder coat the frame and wheels
8. Get new tires
9. ATTEMPTED to use the shep method to fix the mechanical seal but then realized 5 months later that the damage to that area was to extensive and I would need to replace the mechanical seal and the oil seal
10. Discarded the back fender and all fairing
11. Fiber glassed a seat cowl

Other parts I got for the bike included:
1. Anti gravity 4cell Lithium ion battery
2. Motsef regulator
3. Hagon Rear mono shock
4. Progressive front suspension
5. Pod filters
6. headlight and tail light with integrated turn signals
7. Some cheap handlebar grips, clutch leaver and master cylinder
8. Clip on handle bars
9. NKG spark plugs
10. Dime city tacho and speedo
11. BBCR ENG Exhaust system*

*note please don't ever buy from BBCR, even thought the exhaust looks nice I ordered it last September with the promise of it being sent out in 2 weeks, I ended up getting it this May, a whole 9 months later and that was only after I called, email and left a bad review on the owners facebook page even after that he low-key blackmailed me suggesting that "he would send the product out right away after I took the comment down" and didn't even give me the right one because the original product I ordered was discontinued. anyway sorry I am done my rant

By the end of summer 2016, I had done a hell of a lot to the bike but was new to the bike scene, had never really ridden a bike and was 20 (so young and dumb (im still young and dumb)) so naturally I rushed a lot of things to get it finished and did it improperly which meant wasting money. i'm re-doing things because i realized that I wanted this bike to look as good as possible.

Things I messed up because it was rushed or under researched:
1. Destroyed intake boots. I though because the rubber was stiff mean that it was not usable and had to buy new ones
2. Didn't properly seal inside of the gas tank before painting the outside leading to lotttts of rust and having to re do the paint job and line the tank (paint job not done yet)
3. Made a crappy seat cowl (so that will be scrapped soon)
4. cut off some of the important frame tabs including the one that holds the switch which activates the break light

So after that summer I re-assessed the quality which I want the bike to be in and now I am re working the bike

As of this summer I have:
Painted the carbs and the majority of the engine flushed and re built the radiator ad double lined the inside of the gas tank, now I am waiting on some parts including stainless steel bolt from UKBolt to re assemble and put the engine back into the bike

These are the problems I need to solve and things I need to do before the bike is done:
1. figure out what is wrong with my carbs, (the needle from an interior component will not go fully back into the hole) (ins shown in a pic)
2. order speedo cable and gear box (the screw that holds the cable in was seized and I pretty much destroyed the thing trying to gt it out)
3. paint final drive and rear drum
4. re attach engine
5. Figure out whats wrong with the breaks, bleed them maybe (they pistons do not move far enough to provided any braking power when the leaver is squeezed)
6. order a new clutch leaver
7. wire in front lights and gauges
8. Make a new seat cowl
9. paint seat cowl, gas tank and front fender
10. Figure out how if my carbs will without a vacuum hose (ill expand under this list)
11. order 90 jets
12. Shorten clutch and throttle cables

The fuel tank from the cx500 deluxe has a fitting that accepts a petcock with a smaller diameter nut then the one from the gl500 and the the petcocks from the cx500 are not set up for fuel delivery using vacuum so I either need to figure out if my carbs will just work under gravity feeding or if I have to figure out a way to attach the gl500 fuel petcock (could really use some advice on this)

Color Scheme:
Gas tank, cowl and front fender- Monte Carlo Blue (BMW)
Forks and Honda emblems- Zanzibar Metallic (range rover)
Everything else is black

Any way thanks for reading and feel free to critique or comment, ill be posting regularily as I work on my bike often. In the mean time here are some pics! (original bike is my profile pic)


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The new petcock will work just fine. Be sure to block off the vacuum line which used to run to the GL500 vacuum petcock.
 

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Discussion Starter #4
Update: I have finally finished painting the engine and detailing it, to get the bare metal detailing I used a dremel to grind it down and then sand it. I literally had no idea what I was doing so its didn't turn out perfect but it worked, I spentcopious amounts of time trying to find a clear coat that is high temp and can cover bare metal, but living in Canada there where not a lot of options so I just opted out of that. I also managed to paint the final drive and rear drum break. Currently I am waiting for the a speedo gear box to replace then I will put the engine in. In the mean time I will probably try and wire up the front headlight and gauges.

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Discussion Starter #5
SO update on my bike, a lot has happened since the last post, I have pretty much assembled my whole bike, the only thing I have left to make is my seat for the cowl although there are still some problems that I have to deal with. The first is my carbs after flooding my carbs twice and destroying much of my engine and carbs paint job, I cleaned them out and got the bike started, that being said the bike IDLES AT 4000 RPM, its pretty crazy, I am pretty sure its not a vacuum issue although I believe there is a decent sized exhaust leak in between the engine and exhaust mating surfaces which needs to be fixed and I am going to try and re-jet the carbs as well and see if that works! The only other issue I have right now is the electrics, the turn signals are constantly on and I am not sure why, the lights show the high beams and indicators on the dash are also on! I will update soon with pics!
 

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Did you wire up the front set correctly?
They use three wires not two.
One is the running lights, the other is the signal and the third (green) is ground.
 

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Discussion Starter #9
Did you wire up the front set correctly?
They use three wires not two.
One is the running lights, the other is the signal and the third (green) is ground.
Yeh, on the diagram for my head light the three wires indicated are a turn signal wire, a "stop" wire and a ground. I have hooked those up and even switched the turn signal and stop wire to see what happens but it makes no difference. The rear turn signal is also consistently on and to be more specific I mean they are not constantly blinking but like a solid light. I think I may need a new turn signal relay (to handle LEDS) or maybe the mechanical turn signal switch is messed up!
 

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Discussion Starter #10
Here are some new pics of the progress.

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The next picture shows the damage the gas has done to the paint job, I am going to have to touch that up later
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The final pic is the leather color I have chosen for the seat
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You definitely need to swap the flasher module when using LED signals.
If that information had been in the original post you would have gotten this response much sooner.
The original module requires a higher load on it than the new lights have so it will not flash.
 

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Discussion Starter #13
You definitely need to swap the flasher module when using LED signals.
If that information had been in the original post you would have gotten this response much sooner.
The original module requires a higher load on it than the new lights have so it will not flash.

Yeh, I just bought new flasher and will test it out soon.

As for the RPM issue, I tried one re-jetting of the carbs, from 78/112 to 72/105 although that didn't seem to have an effect on the RPM, it was idling fine for for about 5 seconds and then went to 3k were it steadily rose from there to 4k. I changed the intake from air box to pod filter's and the exhaust from stock 2 in 2 to 2 to 1 although I also increased in altitude from about sea level to 1045m (3428 feet), if someone could tell me if that was a step in the right direction in terms of carb jetting then I would be thankful!
 

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Discussion Starter #14
Another question: Does anyone know what the function of the components circled in grey do (apart from the green ground i accidentally circled that)? I am asking because I left/got rid of my fairing with those components in them, if they are involved with my turn signals somehow then they probably are the cause of the issue! Thanks

Wiring Gl500i.jpg
 

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Discussion Starter #17
I have started to figure things out for the turn signals, as in I have been able to make it so that both turn signals are off then the switch is not engaged and the proper turn signal come on when the switch is flipped from right to left, that being said the signals still do not blink. The issue was to to with the speedometer turn signal light, the OEM gl500 had a light for both sides while my aftermarket one only had one light showing that either the left or the right was on so what I originally did was splice the hot wires for both the left and the right turn signal light together and then attach it to the aftermarket bulb, that was the issue because when i cut one of the hot wires it solved the issue (although now it the bulb does not come on for one side).

Now though the turn signals still do not "blink", I have bought a Ep34-L flasher and I will soon be going over all the grounds to make sure I have not missed anything although the new flasher is 3 pronged instead of the two pronged old flasher, sources say that there is a prong for the battery, load and ground and some over sources say that the prongs are for a battery load and indicator light, can anyone confirm or deny this information and let me know if this "3-prong" flasher is the appropriate one?
 

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You have answers to these question in your other thread.
 

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Discussion Starter #19
Update: I has been a while since my last post but I have only recently started to work on the bike again. The turn signal issue got figured out but putting diodes in the wires leading to the turn signal indicator and disconnecting the turn signal running lights (i don't know why the aftermarket headlight even had them). That being said I am getting a new head light and bucket because this one is complete garbage (I have learned my lesson not to but headlights for 30 dollars). I have also bought and installed a new speedo box.
 

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Discussion Starter #20
I also got my seat cushions finished, these are mean for form over function as I don't intend to ride long distances
- I made the cushions myself out of a type of ply wood and those floor mats people put in day cares
- I got the seats professionally upholstered because I didn't have the skill for it

Here are some pics:
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Anyway, next up I have to fix the paint job on the cowl, attach the new headlight, shorten cables, and jet the bike properly

Cheers,
Kris K
 
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