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CX Customization and Modifications
Started by Spacetiger at 12-09-2009 5:48 PM. Topic has 96 replies.
  
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 12-09-2009, 5:48 PM
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Spacetiger
 
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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For some reason, I couldn't post a few pics to a previous thread, so new post.
Working a fork swap and have run into a slight problem, will have to go to the machine shop to get a little work done. I'm sure it will lighten my wallet a bit. Good thing I got the entire GL650 fork assembly for $ 29.99 + shipping; eBay can be a great thing sometimes. I jumped on the fork change because I figured it would cost about the same as getting fork brace…
Anyway, it seems the right lower side fork leg will need some machining to thin up the excess casting so the speedometer gear can move over a bit + I’ll need to reduce the spacer on the left side of the axle and I should be able to get the wheel centered up. So, so much for being cheaper.
A few pics, the axles side by side
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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12-09-2009, 5:49 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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A close up of the GL650, note how thick the lower [right] end is vs. the left side. The GL500 forks have caps on both ends. The GL650 does not, only on the right side.
After the machine work, I’ll try polishing up the lowers + replace the fork seals and oil. Perhaps after Christmas I’ll be able to post some finished fork pics.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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12-09-2009, 9:14 PM
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pwtsvwt
Joined on 08-10-2008
Richfield, NC, USA
Posts 664
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Re: GL650I vs. GL500I fork
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Looks like you've got the right idea. Shouldn't be too bad. You might consider having a little too much removed so that you can bring it back to center with shims. Then you won't have the possibility of taking it back for another set up fee.
Bought on Craigslist - Restored from Ebay: 82 GL500I - now without the "I"
--------------------------------------------------------------
I had all my ducks in a row, but they wondered off!
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12-10-2009, 7:12 AM
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DualSport GL
Joined on 12-04-2009
South Jersey
Posts 24
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Re: GL650I vs. GL500I fork
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First, thanks for the CB900 disk brake upgrade info.
Do u know if the CB900 forks fit the GL? If I remember correctly they are the same size as the GL650 forks.
Are the GL650 triple clamps a direct swap also? Maybe the CB900 is a direct swap also.
1998 Valkyrie Tourer
1981 CB900C 10sp
1999 Dakota CC 4x4 5sp
1986 Mustang GT
1973 340 Duster 4sp, A/C
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12-10-2009, 12:45 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: GL650I vs. GL500I fork
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I think you just have to look up the Honda part numbers to check. even if they are different, I'd bet if you got the tripple tree + forks, it would transfer. I 'd bet the part cross reference for the head bearing would tell you what forks you could swap into the GL/CX 500 models.
That said, I don't think the CB900 had the fork brace the GL650 has. Perhaps someone reading this knows?
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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12-10-2009, 5:44 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: GL650I vs. GL500I fork
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DualSport,
Agree, the aftermarket fork brace is thicker, and therefore probably stronger, but I'd have to be doing some interesting riding to push it that hard to need the stronger brace.
Somewhere before the fork brace is tested, the beefier stanchions from the GL 650I (37mm vs. 35mm) are helping control the overall fork flexing I should think. Overall, I think for the conditions I’ll push the bike, the fork swap should provide a better/controlled ride. But we shall see.
I do know this – the fork swap is another project that’s turning out a bit more expensive than I thought… At least It will be a different looking GL500I on the road.
pwtsvwt - good point on the shims. I was planning on having the machine shop do the work so I know the precision will be there... but if I do it to save $'s, I could use shims to adjust for my "lack of precision". I think I'll ask what it would costs and make my decision then. 1 hr labor = $90. This is probably a 2 hr job, so right at $200 - and you know its right. Or, I can by a tool to help me with this and use shims to correct things. Same cost…. Decisions, decisions.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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12-31-2009, 10:57 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Had a chance to drop off the fork at the machine shop this morning to have some of the lower left side fork removed. This will allow the wheel to be correctly centered.
I was going to do this myself, but I wanted to make sure it was absolutely accurate - only a machine shop can do this (unless you have the correct machines at home).
A few things I noted. Will have to use some washers or shims to mount the brake caliper brackets a bit closer together (The 650 forks are spaced a tad further apart). The caliper bracket bolts will need to be replaced by longer ones (about 3/4" longer) due to the spacing and thicker bosses on the fork legs.
My wallet will be lighter next week, but I can start buttoning up the bike. I have to put the radiator back on, replace the stem bearings, put in the newer calipers (32mm pistons), mount up tires on the GL1000 rims, drill and finish the discs (will attempt a try at polishing the rims before mounting the tires), new master cylinder, and about a half dozen other little things... Riding season is coming in a few months!
Here is a pic of the GL1000 wheel on the 650 fork. The wheel a bit off centered but should come back from the machine shop centered.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 7:58 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Back to the fork upgrade project…
Picked up the GL650 fork today from the machine shop; I had to have some material removed on one of the fork lowers to center the wheel. It turns out they had to shorten the spacer a bit too, but the GL1000 wheel is now centered (the stock rims can work too, but I plan on changing to the reverse ComStar rims). I am $94.30 lighter in the wallet, but I know it is done right. That brings the cost up to $124.99 (+ shipping of the fork). I figured this is comparable to buying an aftermarket fork brace, so this project isn’t getting too expensive to keeping it looking stock.
I now have to clean up the wheel, brakes, and fork – then, polish the bits. Since I’m going this far, I plan to also replace the wheel bearings, rebuild the brake calipers and put new pads in, and rebuild the forks with new bushings and new triple tree tapered bearings. This should keep me busy for the next month or so.
I post to this thread so you can track completion of this series of mini projects.
Here are a few pictures of what it looks like. I suspended the fork from the garage opener frame and ran a red bungee cord from the ladder to the wheel to hold the fork in about the right orientation.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 8:00 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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A side angle picture of the wheel and brake on fork. I swapped in the polished speedometer gearbox on the axle to see how polished aluminum would look. Hopefully, the wheel will come out this polished along with the stock brackets and calipers too.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 8:01 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Another side [close up] picture of the wheel.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 12:42 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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degrease cleaning, wet sanding, and some polishing (to break up the routine).
The wheel starting to look clean (and partial wet sanded)
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 12:44 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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The forks and brace. Both forks washed and wet sanded. The fork on the left has some polishing time (as does the brace).
Time to run to the store for stronger paint stripper. It is much harder to get the paint off the front calipers and bracket than I thought
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 6:02 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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One caliper and one bracket stripped of paint during an episode of 24 with Jack Bouer…
Another set to go during the week, then off to the sanding, then polishing they will go – perhaps by next weekend.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-18-2010, 9:23 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,863
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Re: GL650I vs. GL500I fork
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Was that the two hour episode?
Since you have it off is there any difference between the left and right brake bracket?
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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01-19-2010, 2:49 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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yes and yes
brackets at the top are stock left and right GL500I brackets
Below, are GL 1100 brackets left and right.
left and right are different.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-23-2010, 3:17 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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I'm getting the brakes stripped and cleaned before polishing. Brackets and left caliper just about done (one the 220 sanding to go)
I found out the GL 1100 calipers (32mm dual pot calipers) came with a surprise. Seems the right one has 25mm pistons. Thinking this was an error, I got another one... it was 25mm too! I'm guessing the right leg has an anti-dive or something to bleed off pressure, so they have smaller pistons. In any case, I had to find another Honda bike that used a right side caliper with 32mm pistons so I could have balanced pressure on the discs…
After some research, I only found a few models that used 32mm dual pot pistons:
83-86 V65 Magna, Sabre
83-86 V45 Interceptors
83 CX650T
84-87 GL 1200’s did not (25mm as well).
Seems most bikes used 30mm pistons (CB 900, 750’s, 650’s, V30’s, V45 Magna…)
So, if you are going to swap to 32mm pistons dual pot calipers, you will have to hunt for a right caliper. I got luck and found a V45 Interceptor today for $14.95 + shipping.
Since I will be delayed from getting the right caliper, I can take my time tomorrow to finish cleaning the wheel, final sand the current brake parts, then start polishing the other fork lek, wheels and brake items.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-24-2010, 3:10 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Well the Jets are going down...
But I got some work done anyways. Finished left caliper, brackets, and fork - or as good as I'll get them.
Wheel and right caliper still to clean and polish.
Then its:
1. replace seals in fork (have to get kit),
2. mount tire (still to buy),
3. rebuild brakes (have kits),
4. replace wheel bearings, then
5. put it all back on with new tapered bearings...
Then I can put the electric fan on...
pic 1.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-24-2010, 3:10 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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another view; rotated correctly.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-27-2010, 7:12 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Well the right caliper came in today along with all the other parts/ It will be a busy weekend.
These are the only bikes I could find that use both 32mm caliper pistons for right and left forks.
V65 Magna
V45 Interceptor
CX 650T
V65 Sabre
CB 700SC (found this out yesterday)
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-30-2010, 9:54 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Removed most of the paint, soda blasting next, then sanding and polishing for the right caliper.
If I make good progress today on the caliper, I'should be able to get the triple tree installed with new taper bearings in by Sunday. I will replace the seals and dust caps on the forks before installing them.
Here is a pic of the caliper so far.
.
Here is
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-30-2010, 10:01 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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As a side note, the right caliper bracket was the same (GL 1100 vs 83 VF750 Interceptor), so if you are looking to make the swap to twin 280mm dics then the caliper brackets you would look for can include:
83-86 VF750 Interceptor
84-86 CB700SC
If you can get the entire front brake setup to include the calipers, than you get the 32mm twin piston calipers too.
If you get the GL 1100 brackets, you can only get the left 32mm piston caliper, the right is 25mm dual pistons.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-31-2010, 3:15 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Time to get the fork back on.
Today I worked to get the triple tree back on but had to get the new tapered bearings on. I bought the set to go on the GL 500 I forks, but they also work on the GL 650 forks.
It took a bit of effort to get the races off the triple tree, but a little heat and leverage did the trick.
I used the old race [inverted] from the stem head to protect the new bearing before tapping the new bearing on the triple tree. Here is a pic of the race on the bearing.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-31-2010, 3:16 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Then I slid a pipe fitting to tap on with the hammer
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-31-2010, 3:17 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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The bearing tapped into place.
Good thing I remembered to get the bearing seal ion 1st...
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-31-2010, 3:21 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Then, its grease time in and around both bearings, then the tripple tree goes on.
I added the fork lower to check fitment. I will have to remove them again to replace the seals and dust seal. THen I can mount them up and add all the bits back on.
Then, it will be on to the front wheel/brakes. Since its cold, I will be polishing indoors the next few days.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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01-31-2010, 8:09 PM
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Panther
Joined on 05-09-2006
Las Vegas, NV
Posts 1,264
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Re: GL650I vs. GL500I fork
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Looking Great!
I can't wait to see how it all comes out.
and to hear what you think of the 32mm brakes.
Peace & Light
>^..^<
..........
'83 GL650swi "My Little Grey Lady"
'82 GL500swi parts bike
'78 DT175
'86 LS650 Milady's bike
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02-02-2010, 4:31 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Its going slowwwwww.
Here is the sanded right caliper - used 150, 220, 400, 800. Time to start polishing...
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-02-2010, 5:13 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,863
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Re: GL650I vs. GL500I fork
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Are you going to be putting some rubber on that rim soon?
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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02-02-2010, 5:59 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Blindstich,
I thought I'd try the Fred Flintstone ride first... just kidding.
Yes, but I want to get the fork on 1st and put the original wheel/tire on so I can check the rear to make sure the GL 1000 rear wheel fits the hub. Once confirmed, I will polish the GL 1000 wheels then mount the new rubber (Dunlop D404) on the front.
Have to do the forks tomorrow.
Here is the caliper polished - as good as I'm going to do now.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-02-2010, 6:00 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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another view
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-02-2010, 6:01 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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here is a look at the front wheel on the fork.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-02-2010, 6:18 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is what the rear wheel looks like.
The rear disc is a 6 hole mount to the wheel, the current GL 1100 wheel uses a 5 hole mount. What is to be determined is what impact, if any, will the new disc have to the rear caliper so it matches up to the disc. I may have to modify the caliper bracket. The current factory design uses a bracket that fits on the axle. If I have to change the caliper mount, I'll have a simple "L" bracket made to mount to the swingarm and mount a front fork style caliper bracket to it. I may also have the rear disc trimmed in diameter so the braking surface is reduced. The dual pot caliper does not require near the surface area. This will also reduce my potential to lock the rear brakes.
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-05-2010, 4:05 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Its starting to snow (12-24" expected) in DC so we got to get off early.
I mounted the old front wheel so I could check the rear GL 1000 compatability.
I pulled the rear wheel to see what the compairison was and check final drive fit (on and off bike) and to remount everything to check rear brake alignment.
Here is a pic with the wheels off.
,
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-05-2010, 4:07 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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fit check the final drive - and found 1st challange, Seems the GL 1000 has 8 ridges in the interior of the wheel that prevent the GL 500 final drive from fitting.
Here is a pic of the ridges.
.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-05-2010, 4:14 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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I took the small grinding stone that mounts to a drill and went to work griding down the ridges, Then I clened off the dirt between the ridges, Still no joy in getting the final drive to fit. The wheel housing is just a tad too thick - so, I removed the spacer on the final drive to test fit the drive/gear engagement. I works.
Here is a pic of the ground down ridges.
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-05-2010, 4:16 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: GL650I vs. GL500I fork
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Test mounted the wheel to check brake alignment.
Rnning into a problem as the wheel is not centered and brake is about 3/16 to far to the left..
Have to do some measurements... but 1st, time to shovel some snow.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-06-2010, 7:02 PM
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AggieGL650
Joined on 10-26-2008
Fort Worth, TX
Posts 111
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Re: GL650I vs. GL500I fork
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Jerry -
Hope you're coping with the snow. I checked in on my cousin in Burke and never heard back.
You've got quite an interesting project as well. I'm dealing with my forks and front calipers now as well. I was going to strip the calipers per Larry's polishing instructions, but it didn't work. From reading your thread, it appears that the anodizing can be removed with paint stripper - what kind did you use? Also, what did you use to polish the calipers with? The small polishing "brushes" I have are felt, and don't seem to do nearly as well as the larger cotton (I think that's what they are) wheels.
The rear disc setup you've got is very impressive. I may do that for version 2.0, but I've got to get 1.0 done first...
1983 GL650 cafe in progress
2002 Suzuki SV650 (Ol ' Yeller)
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02-06-2010, 10:10 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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AggieGL650,
We got about 30" of snow. After digging out, I helped 5 other neighbors - I have a snow blower. Burke probably got that much too.
The product is called stripper. I included a pic of the can, pic is blurry, but you can tell what it looks like. You can get it at Walmart or Home Depot
I found the best way to use it was to spray a small area of the caliper and then let it sit for 5 min. Then, I used a small wire brush with the surface area of 1/2 toothbrush to softly swirl the brush to remove the paint (anodizing). Then rinse with warm water using a toothbrush to wash off everything. Then move to another section. WEAR GOOD GLOVES AND EYE PROTECTION!
After stripped, I sanded the caliper body. 150, 220, 400, 800, 1,000. I bought one of those sponge sanding blocks (~$3) at 150 grit. It didn't last very long but, the block was a good size to use with wet/dry sand paper. Go to 220, 400. I used 800, then 1000 on the front (HONDA emblem). I got a fine metal file and only had to use it in a couple of spots for both calipers before sanding. I also used a dremil tool with sanding thingy attached to get at a couple of spots.
For polishing, I used red compound 1st on a 6" wheel. Then I used green on a 6" wheel. Then I used a dremil tool polishing wheel with green compound. I used a aluminum polish last to clean up the calipers.
Thanks on the rear caliper. I don't know if I can say it’s a better brake than the drum - but using the GL 1100 17" rear wheel dropped the RPMs a few hundred RPM. The difference is noticeable at 60+. I would say it is worth doing for this alone. If I can get the GL 1000 wheel to work, then I know the GL 1000 wire wheels can be made to work. I'd like to see what a CX or GL would look like with wire wheels.
I'll work on it tomorrow before the big game.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-06-2010, 11:05 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,863
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Re: GL650I vs. GL500I fork
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Also don't get it on you. It burns. I had some rubber gloves on and moved a part I was doing around while it was foamy and it ate the tips of them.
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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02-07-2010, 5:27 AM
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AggieGL650
Joined on 10-26-2008
Fort Worth, TX
Posts 111
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Re: GL650I vs. GL500I fork
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Thanks, Jerry. Sounds like I may have defined the start of my afternoon...
I agree, Stitch. I've got a box of latex gloves and some heavy duty rubber gloves, but i never remember to use them until it's too late.
I had to quite cleaning the paint off my hands with paint thinner yesterday because it was starting to look like I had acid burns...
1983 GL650 cafe in progress
2002 Suzuki SV650 (Ol ' Yeller)
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02-07-2010, 5:28 AM
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AggieGL650
Joined on 10-26-2008
Fort Worth, TX
Posts 111
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Re: GL650I vs. GL500I fork
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Oh, and I completely agree with you on the wire wheels. That's on the list for v2.0 as well.
1983 GL650 cafe in progress
2002 Suzuki SV650 (Ol ' Yeller)
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02-07-2010, 8:50 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: GL650I vs. GL500I fork
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AggieGL650,
So, not to rush you or anything, but what is on the list of 2.0 mods? Just curious; for me, its get another bike - LOL. I only have a few more mods to make to complete this bike to be the GL model I always wanted.
I will get out in the garage to do some measuring to see what needs to be done to make the GL 1000 wheel work.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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Report
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02-07-2010, 2:01 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Measurements done.
I slid the rear axle through the final drive on the GL 1100 rear wheel, with the spacer, rear brake caliper bracket and spacer washer – then I drew a line on the axle.
See pic.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-07-2010, 2:02 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Then, I did the same thing with the GL 1000 rear wheel – the line clearly shows this set up is thicker.
See pic
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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Report
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02-07-2010, 2:03 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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In checking the final drive to wheel fit, it becomes clear, the final drive flange for the GL 1000 wheel is too tall – it is preventing the final drive from setting further into the wheel.
Here is a pic of the GL 500 wheel (left) compared to the GL 1100 (right). The drive flange for the GL 1100 sits further back than the GL 500. This makes it easy to swap these wheels.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-07-2010, 2:04 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a pic of the GL 1000 flange. I will need to get a gear puller to take it off, then have some machine work done to trim about 3/16” off the end. When this is done, the final drive will slide closer to the wheel. There will be plenty of teeth depth left for engagement with the GL 500 final drive.
To save money, I will attempt to sand down the inside of the wheel to accept the final drive guard and only farm out the rear drive flange. The good news is that the rear disc may line up so I do not have to go to plan B, but I will not know for sure until I can mount up the rear wheel. This will take another week…
Jerry
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90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-07-2010, 3:59 PM
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AggieGL650
Joined on 10-26-2008
Fort Worth, TX
Posts 111
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Re: GL650I vs. GL500I fork
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Jerry:
2.0 would be wire wheels and possibly a beefier fork. I would also like to build a seat that like an original CB750. The way I've got the cafe seat set up, I could switch between the two in a few minutes. That seat and the wire wheels would give it a more classic look. Who knows if I'll do it, but I like the way it looks in my mind...
I've spent a good portion of the afternoon trying to strip the anodize coating off of one of the brake calipers. I'm not using the spray you did, but some gel stripper that I used to clean my wheels with. After 15 minutes, steel wool was helpful, but it was work. 4 applications left me with about 40% still on. I got tired and came inside.
What kind of attachment did you use on your dremel? Didn't you say that you used it to clean the nooks and crannies?
Jeff
1983 GL650 cafe in progress
2002 Suzuki SV650 (Ol ' Yeller)
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02-07-2010, 8:06 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Jeff,
I only used the dremel for final sanding in the nooks, THere is an attachment you can get that looks like a donut about the diameter of a half dollar. It comes in 180 or 320 grit. I didn't use it to strip paint but to sand. You need to get e can of the stripper stuff - Blindstich recomended it and I'm going to endorse it. It really works.
My wife didn't give me too much grief, I used the ss kitch sink and made sure really cleaned up after myself. You really need some small wire (ss or brass wire) brushes/ You can get these at Home Depot as well (I did).
Because of the final drive, the GL 1000 wire wheels are a natural swap; 100/90-19" front and 130/90-17" rear. I think you may only have to mod the drive flange outter wheel to final drive housing and rear axle.
Have you figured out which fork you are considering? I thought the GL 650 were 39mm or was it 37mm? The GL 500 were 35mm. What ever you get, you will have to get the tripple tree, Make sure they have dual brakes. Depending on what you get, you may need to swap brakes as the caliper brakets may not work on your new forks. Or, if $'s are not to big a deal, you can try these guys:
http://www.fishheadbigbrakes.com/
I emailed Dan, he said no problem modifying a set of really nice aftermarket brakes with big discs (don't be shocked when you see the cost - I bet close to $1,000. But, you get new discs, calipers and custom brackets made to fit your fork and wheel)
Here is a pic of a kit for the GL 1000 wheel.
If $'s don't grow on trees like the rest of us, you will have to go with Honda engineering from other bikes.
.
Jerry
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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02-08-2010, 1:04 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Got the flange pulled off (had to use a small gear puller); it was on really tight.
After it was off took several checks to verify what was causing the packaging issue. It turns out the final drive cannot slide onto the wheel far enough because of a lip on the wheel. This lip prevents the final drive from sliding closer to the wheel. The problem is not just the flange.
Here is a pic of the backside of the flange on the final drive. You can see the width of the teeth on the final drive match up with the width of the teeth on the flange (look inside of the flange). If the final drive teeth were wider, they would stick further into the flange; as there is nothing inside the flange to stop the final drive from moving further inside – except the lip on the wheel. Now, if I just trim the 2nd diameter lip on the wheel, the thickness of the flange would prevent the final drive from closing closer to the wheel.
90 PC 800 (commuting steed)
82 GL500I (50+mpg, great bike)
66 BMW R 50/2 (No brakes/HP)
80 CX500C (Loved this bike)
74 CB360 (Fun; but too small)
79 CX500D (40,000+ mi in 3 years)
76 CB550 (step up from 200cc)
74 KZ200 (1st bike!)
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Honda CX500 & G... » CX500 GL500 Tra... » CX Customizatio... » GL650I vs. GL500I fork_Fork mods done_7 Mar 2010
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