Honda CX 500 Forum banner

1 - 20 of 997 Posts

·
Registered
Joined
·
1,218 Posts
Discussion Starter #1 (Edited)
Hello everyone,

As with many members on here, I figure I should document my (slow) cafe racer build and maybe get your guys opinion along the way on a few things. I love getting inspiration from others builds and a lot of the things that I do to my bike come from other great members out there.

First a little back story: For as long as I can remember I've always wanted a motorcycle, but never had the money to get one. Last year I was searching the web when this 1980 cx500 custom caught my eye. What a cool looking bike I thought. Long story short I went and picked up my first ever bike and I was so happy. Got it for $250, and knew I had lots to do, starting off with replacing the stator. (Also the PO did not have the ownership and it was an american bike....that took a while to get worked out lol) Fixed it up and it ran great after a little tuning. At that point in time i just wanted to have a bike to ride so I didn't do much to make it look pretty, but now that i have a bit of extra cash (I don't really lol) I want to get it running better and looking fantastic.


Index

Page 1: Background, front fork rebuild, front fender chop, clip-on handlebars, new exhaust wrap and mufflers, new headlight and front signals.
Page 2: New engine new temperature gauge.
Page 3: Painted engine tags and clutch cover.
Page 4: New temperature sending unit.
Page 5: Radiator guard design.
Page 6: Engine paint prep, gauge design and radiator guard fabrication.
Page 7: Dummy lights and gauge redesign
Page 8: Muffler repacking, new tachometer and speedometer, engine painting, engine guards and shock painting, frame touch-up and engine mounting.
Page 9: E-fan mounting and wiring.
Page 10: Redesigned e-fan mounting and steering limits.
Page 11: Gauge and dummy lights wiring and gauge mounting brackets fabrication.
Page 12: Gauge brackets redesign and fabrication.
Page 13: Gauge brackets painting, dummy lights mounting, gauge mounting, lights testing and carb cleaning.
Page 14: Bike startup and oil leak.
Page 15: Cylinder cover painting and test drive.
Page 17: Rim tape installation.
Page 18: Bike drawing start, LED strip testing and tank designs.
Page 19: Rear fender and licence plate holder design.
Page 20: Tank designs, rear fender redesign, bike disassembly and tire hugger design.
Page 21: Tire hugger design and brake light switch bracket fabrication.
Page 22: Battery box design and fabrication.
Page 23: Battery box fabrication and painting and rear fender support tubes fabrication.
Page 25: Rear fender support tubes and rear fender fabrication.
Page 26: Rear fender fabrication.
Page 27: Rear fender mounting bracket fabrication and start of rear fender assembly.
Page 28: Rear fender assembly, test fit and more fabrication.
Page 29: Licence plate bracket design and fabrication, final rear fender assembly, turn signal testing/concept and rear frame modifications.
Page 30: More rear light ideas.
Page 31: Rear hoop and signal mounts fabrication.
Page 32: Rear hoop fabrication continued, new shocks and signal test fit.
Page 34: Rear hoop mock-up, shock limiters, rear hoop modification, rear fender mounting bracket clean up, front electronic pan fabrication.
Page 35: Rear electrical pan fabrication, license plate bracket fabrication and rear fender test fit.
Page 36: Licence plate lights, regulator and starter solenoid mounting and wiring and rear tire hugger fabrication.
Page 39: Rear brake pad replacement, rear hub painting, frame clean up and welding in rear hoop.
Page 40: Priming and painting frame.
Page 41: Getting tire hugger and rear fender ready for painting.
Page 42: Rear fender inside coating.
Page 43: Rear fender and license plate painting, new shock spring coating, shock assemble and install and rear fender, tire hugger and turn signal mounting.
Page 45: 12 Volt time delay modules.
Page 46: Wiring and painting of rear tire hugger and electrical pans.
Page 47: Mounting tire hugger and electrical pans and wiring battery and starter solenoid.
Page 48: Cleaning up electronics and wiring rear turn signals.
Page 49: Pod filters.
Page 50: Header breather tubes and front fork stiffness modifications.
Page 51: New LED brake and running light.
Page 52: Brake flasher module.
Page 53: Brake light mounting and electronic testing.
Page 55: Tire choices.
Page 57: Disc lock.
Page 58: Final Tank designs.
Page 60: Seat pan mock up and fabrication.
Page 62: Changing tires and paint supplies.
Page 63: Tank stripping and seat upholstered.
Page 64: Priming gas tank and new ignition switch.
Page 65: Painting gas tank.
Page 67: Wet sanding tank.
Page 68: Fixing tank mistake, building ignition switch, final 2K clear coat on tank and buffing/polishing tank.
Page 69: Bike pictures and tire hugger mounting clarification.
Page 70: More bike pictures.


Anyways, here are some pictures from before:

How it looked when I bought it:

IMG_3492.JPG
IMG_3493.JPG

First time taking the engine out:

IMG_3799.JPG
IMG_4024.JPG

Repainting the tank (temporary):

IMG_4025.JPG
IMG_4055.JPG

Redone seat cover (temporary):

IMG_4319.JPG

The bike as it stood last year before any serious mods:

IMG_5066.JPG
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #3
First thing I did was rebuild and paint the front forks:

IMG_5813.JPG

Painted the wheels with black rim paint and matte clear coat:

IMG_5814.JPG

Trimmed and cut the front fender:

IMG_7432.JPG

All together (fender is just laid in place):

IMG_7433.JPG

Next step was to redo the front headlights, signals, handlebars, mirrors and clean up the rats nest of wiring behind the headlight bucket.
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #4
Took off the stock headlight and WOW....what a lot of old wires. Someone had been back there before and made a hack job of a lot of the connectors. Shortened everything to a good length and put all the connectors and fuses into a project box mounted on the front. Painted it black and it seems to blend in pretty good. Over the winter I would like to redo it all again and tuck it all under the tank.

What a mess:

IMG_7690.JPG
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #5 (Edited)
All of the parts I purchased for the first round of modifications:

IMG_7524.JPG

Got rid of the old handlebars and put on some clip-ons. Bought new brake assembly as well seeing as the old one was in pretty rough shape.
Painted the top of the triple clamp black for now. I may make it a bit smoother looking later on.

IMG_8190.JPG

Also wrapped the headers in a black fiberglass wrap, although it is more of a gunmetal color now that it has dried and baked on a bit. I may change this or not.....who knows lol.

IMG_8180.JPG

Annnnnnnnnnnnnd new exhaust. Making the brackets sucked.....but i think they turned out alright (a little rough though I know).
You can also see the new foot pegs. What are they made of? BMX pegs and grip tape lol. Saved me from machining them and they were pretty cheap too. I think they don't look too bad, maybe a little big is my only complaint. But for now they work good, and the grip tape helps my feet stay on them really well.

IMG_8181.JPG
IMG_8184.JPG
 

·
Registered
Joined
·
89 Posts
Hello neighbour! That's shaping up pretty nicely. I wana do a cafe too with the spare CX I got. Well I say that but time and money and excuses are what's happening right now. :) Can't wait to see yours!
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #7
Hello neighbour! That's shaping up pretty nicely. I wana do a cafe too with the spare CX I got. Well I say that but time and money and excuses are what's happening right now. :) Can't wait to see yours!
Hey, its good to see a fellow Cambridgean with a cx500 finally :D Once i get my bike running again we'll have to meet up sometime!
And I hear you lol, money and time are my biggest enemies haha.
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #8 (Edited)
Bike was acting up, so new coils, new caps, new plugs.....and a little bit of red expandable sleeving to make her look good, and she was running a lot better.

IMG_8177.JPG

New headlight with a cool startup feature that I didn't know about. Me likey :eagerness:


And pics of it mounted on the bike with new turn signals:

IMG_8186.JPG
IMG_8188.JPG

Of course....all these fancy new lights and gizmos means I need a new version of the most important thing on the bike........the horn...

IMG_8187.JPG

And lastly what the beastie looked like when I finished stage 1 of the front end. Slowly turning into a cafe racer....ish:

fotofriend_3682247.jpg

IMG_8194.JPG
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #9
Just noticed some of my pictures are upside down when viewed on an iPhone or if you click to see the full picture :confused: Sorry about that, I'll try to resolve the issue for the rest of the posts.
 

·
Registered
Joined
·
2,167 Posts
Hey Micah,you get that motor finished and installed yet??
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #11
Hey Micah,you get that motor finished and installed yet??
Cleaned it up, Took off the rad and rear cover, changed the stator out for my G8 one, and just waiting for the Cam Chain to come in the mail now. Gonna pull the rotor/flywheel tonight, and maybe start making the power relay and temp switch circuit for the e-fan.
I also bought a new water temp gauge so I need to make myself a 7v regulator. Lots to do lol, but I'm enjoying it for the most part :)
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #12
This is about the point where my motor seized on me.......yeah.....it sucks. Took it out and found brass flecks in the oil.....looks like a bearing went on me.
Instead of putting a lot of money into a high mileage engine (59,000 miles) to get it redone, i decided i would look around for a new engine. Forum member Kameron had one lying around and I picked it up about two weeks ago now. (Thanks again!)
I'm in the process of changing the cam chain and seals as well as putting the newer stator and clutch plates in from my bike.

My bike as she stands currently :(

IMG_8205.JPG

New engine to work on though :)

IMG_8231.JPG
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #14 (Edited)
Headlight looks amazing! Did you place an led strip on the inside?
Thanks Skyler, I really like it too. It was just what i was looking for. Something with a classic look but modern technology....and i really liked the halo feature lol
The headlight light along with the CCFL halo is all one unit. No mods done or anything. It comes with four wires; ground, running light, high beam and the halo. I just plugged the halo wire into an extra 12V wire coming from the ignition.

I was just looking for anyone else selling the black version of the light but can't find it anywhere anymore. Here is the chrome version of the light though: Amazon.com: BikeMaster Angel Halo Headlight with CCFL - Chrome FA54 CHR: Automotive

Edit: I found the headlight in black here: http://www.amazon.com/gp/product/B007GR4FCO/ref=oh_aui_detailpage_o05_s00?ie=UTF8&psc=1
 

·
Registered
Joined
·
387 Posts

·
Registered
Joined
·
1,218 Posts
Discussion Starter #16
Farmer john: I think I remember seeing that one when I was looking for a headlight. It's a nice combination but I didn't like the "boxy" shape of the rear of the headlight. Still a nice light though!

And there was no extra room at all inside the new headlight as it is only a 5" one I believe. Rather than have all the connectors and wiring sticking out I wanted to clean it up a bit. So I bought a project box (basically just a plastic box) that fit between the forks. I then trimmed all the connectors and wires making it all a bit neater. Stuffed what I could inside the box including the fuses and just put split loom on the wires coming out.
You can sort of see it tucked behind the horn in the one picture.
Over the winter I want to put it all under the tank though, and just have nice covered wires going to all the components.
 

·
Registered
Joined
·
3,803 Posts
Hey Farmer John, Thanks for that link.
Now i know what I will be using when the fairing comes off permanently.
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #18
Flywheel/Rotor is off, surfaces are prepped for new gaskets, Mech seal cup is cleaned and ready to receive new parts, and G8 Stator is in place. Tonight I'll hopefully change over the clutch plates. Hopefully the cam chain and gaskets comes soon!

In the meantime I've been fooling around with the engine tag colors that I might do. What are your guys opinions?

Honda Logo.png
 

·
Registered
Joined
·
1,218 Posts
Discussion Starter #20
New coolant temp gauge came today as well as the relay to do the e-fan conversion. Still lots to do on the new engine but she's coming along slowly. Looking at getting some paint for the engine. Originally I was going to do an aluminum color....but the darker cast iron has caught my eye............

Here is the gauge. I'm sure you've all seen it before though lol. I didn't know it came with adapters and a sending unit so that was a pleasant surprise:

IMG_8324.JPG
 
1 - 20 of 997 Posts
Top