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You'd be better off buying another engine.
 

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1981 CX500C
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473 Posts
FWIW. The cylinder has a steel/ iron liner. The aluminum case is cracked at the cylinder. Likely caused by an over heat event.

Your best path is to replace the engine. A new head gasket will have a difficult task to seal those cracks.

Good Luck
 

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82 GL500, 78 CX500
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If it cannot be welded in some way, replace the block. I would completely disassemble the engine, completely clean the block and then take it to a welding shop. Welding might work, might not.
 

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82 GL500, 78 CX500
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189 Posts
Any welding is done on the aluminum, not the steel. It can be welded. How long the weld last, that part is questionable. But I agree with the rest. Probably be better to find another engine.
 

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Discussion Starter · #8 ·
Do you know the difference between the block of a cx 650 and cx500? An older motorcycle rebuilder I'm planning on working for has an old cx500 motor laying around, and he could help me rebuild it from ground up. Did they just change the stroke? Or is the bore massively different?
 

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They changed the bore and the stroke. 500 has a 78 mm bore. 650 has 82 mm bore.

The engines are very similar but little actually interchanges.
 

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1978 CX500 "The Grub", 1983 GL650I "Nimbus"
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12,658 Posts
Rear covers are identical (GL500), except for the hole for the manual chain tensioner. Front cover is the same, other than the drain plug. The clutch cover and oil filter might be direct swaps.
Everything between is different.
 

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'84 CX650E that is evolving into a GL500
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The valve covers are different but interchangeable. The clutch plates & discs are the same but the 650 has one more of each. And if you want to get picky many of the bolts are the same.

How complete is the GL500 engine?
 
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