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CX Customization and Modifications
Started by Doward at 05-20-2008 4:53 PM. Topic has 163 replies.
  
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 05-20-2008, 4:53 PM
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Doward
 
Joined on 05-11-2008
Alachua, FL
Posts 814
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Buddy of mine and I split the $400 a gentleman wanted for a '78 CX500 and an '81 CX500 Custom (not a deluxe as I thought)
Needed to get another frame for the '78, which a member here provided free of charge! One 1980 CX500 Custom frame secured. Awesome way to get introduced to the community, I might add ;)
That said, the '78 is currently completely disassembled. The '80 frame is completely cleaned and refurbished. Here's the pics (sorry for no in-progress pics)
What I started with (click on the thumbnails for larger pics):
How the '78 looks now:
How the '80 looks now (and I will update my avatar as it comes along):
The engine/tranny (I LOVE how easy that thing is to slide out!)
1978 CX500 motor + 1980 CX500C frame
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05-20-2008, 5:04 PM
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tntchitwood
Joined on 03-02-2008
Pine Knot, KY
Posts 511
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That's how alot of us started out. Did you hear them run?
'82 Silverwing Chopper
'02 750 Shadow
http://choppercharles.com/cs/forums/29599/ShowPost.aspx
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05-20-2008, 5:52 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Negative - so I'm doing the smart thing, and assuming the worst ;)
Going to check everything over and perform the triple bypass while the engine is out!
1978 CX500 motor + 1980 CX500C frame
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05-21-2008, 6:19 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Alright, so the swing arm is now totally disassembled. Cleaned it thoroughly, was both happy and aggrevated to see it packed full of grease. Yes, it was greased, good - but damn cleaning that all out made a MESS. Cleaned the rear drive assembly, and had a dead o-ring greet me when I pulled it from the rear wheel.
So I'm debating now if I should pull the rear drive assembly apart, and re-pack all the bearings, new seals, etc. It'd be extremely easy to get off the bike once the bike is together, and the assembly feels nice and tight as it is. I may just replace whatever this O ring that was between the rear gear assembly and wheel is, and let it ride out.
Updating avater with the newest pic now. I'll update this thread tomorrow with more pictures (after I get the swing arm back on)
Today got the main/side stands in, and the triple tree all cleaned/painted up (it is set on, but not bolted down until I get the proper bearings) and the swing arm disassembled.
1978 CX500 motor + 1980 CX500C frame
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05-22-2008, 8:13 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Didn't get nearly as much done this afternoon as I wanted to (worked late today :-( )
BUT - I did get the swingarm cleaned/painted/remounted!
1978 CX500 motor + 1980 CX500C frame
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05-22-2008, 10:36 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Got the final drive assembly pulled off, cleaned up. Pulled the retainer - and now I find I need some kind of 'final retainer' wrench. Might just order one up :-)
The assembly was leaking gear oil from the 'weep hole' at the bottom. When I pulled the assembly from the wheel, there was a destroyed O-ring awaiting me.
1978 CX500 motor + 1980 CX500C frame
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05-23-2008, 2:06 PM
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RichNCT
Joined on 03-02-2006
Connecticut, USA
Posts 3,463
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Sounds like you are disassembling the final drive. Reassemble it just like it came apart as regards the spacer washers and such. The proper setup of the gear lash is critical to long life, and most of us are not equipped to do it. The alternative, as I said, is to put it back together like it was. There is another (2nd o-ring) smaller seal farther inside, this is often still not leaking. Further disassembly is required to get to that one, ill advised unless you are more adventuresome than I. Used drives are very reasonably priced too. Special tools when I did my GL650 big seal was a hammer and brass drift. Still good 2 years later.
Refueling on The James Bay Road, 2009
Born to be relatively wild (for a grampa x 3)
GL650I, CX650E, CX650T
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05-24-2008, 9:27 AM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Sounds good to me. I've rebuilt automotive rear ends before, so I know how critical backlash, preload, gear teeth contact, etc is. I'll be disassembling the final drive today (with pics, since I can't find any of that being done on here - most seem to just swap it out, since they ARE really cheap)
1978 CX500 motor + 1980 CX500C frame
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05-24-2008, 10:47 AM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Alright, using a drift and a hammer, we get this:
1978 CX500 motor + 1980 CX500C frame
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05-26-2008, 1:26 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Heading down tomorrow to order the 3 o-rings for the final drive/rear wheel assembly.
So I thought I'd start working on my front forks!
I've already got new seals, and new wipers for them. Disassembled one side so far today - and someone rebuilt them wrong.
The spacer that is supposed to be between the springs was above the top spring, above the oil seal (which is one of those cheap non-metal-backing ones, btw) and the oil came out as a milkshake.
The fork tubes had the barest bit of rust on them, so I hit them with 320-600-1000-Mother's Billet Polish to cleam them up. What do you guys use to protect them, though? Just a light coating of WD-40 or what?
I'm thinking of doing the lower fork tube holders in a satin-black finish, to match the frame.
1978 CX500 motor + 1980 CX500C frame
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10-03-2009, 6:26 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Now here's a thread that we haven't seen in a while!
What has over a year of work accomplished?
A running bike, that's what ;)
Ended up replacing the throttle cables and the clutch cable, powdercoating the carb inlets / tops, the valve covers, the kickstand, the handlebar, and well - it just keeps going ;)
I am now missing the headlight system (which I'm purchasing from a member here, sending the money order to him Monday, since I didn't make it yesterday!) and the brake light.
The latest snafu was that the headlight control switch I had was for a 79+, which is different from a 1978 wiring harness. Thankfully, I had a spare harness here, so I pulled out the diagrams and went to work. That has yielded the following:
http://www.youtube.com/watch?v=MZpPuxMCqz0
1978 CX500 motor + 1980 CX500C frame
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10-03-2009, 9:07 PM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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Nice work Doward, another one saved from the scrap heap.
If you're still in control...You're not going fast enough.
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10-03-2009, 9:57 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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 BearCX wrote: | Nice work Doward, another one saved from the scrap heap.
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So far I've been real pleased with the bike. Seems to spin a few more RPMs than I'm really comfortable with, but overall it's a fun little bike.
I should also mention that this is the first motorized two wheeled contraption I've ever taken for a spin! I see why motorcycling is so damn addicting!
A couple of pics from today: (yes, I know the seat needs recovering!)
1978 CX500 motor + 1980 CX500C frame
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10-06-2009, 7:46 PM
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Clumzi
Joined on 01-26-2009
Olympia Washington
Posts 636
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They are fun little bastards, aren't they? -nick
1979 CX Rat Sport
(EMGO pods, wrapped MAC 2in1, 90/130 re-jet, 18" rear wheel, 50 cal ammo cans, Viper cafe faring, $.97 rattle can flat black)
1987 Toyota Van (Whitey)
2002 Subaru Legacy GT (Spiffy)
Motorcycles should be black and dirty :)
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10-06-2009, 8:29 PM
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Panther
Joined on 05-09-2006
Las Vegas, NV
Posts 1,264
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| Doward wrote: |
I should also mention that this is the first motorized two wheeled contraption I've ever taken for a spin! I see why motorcycling is so damn addicting!
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Looking good!
Might I suggest the beginners riders course?
http://www.msf-usa.org/
Peace & Light
>^..^<
..........
'83 GL650swi "My Little Grey Lady"
'82 GL500swi parts bike
'78 DT175
'86 LS650 Milady's bike
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10-07-2009, 12:09 AM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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I'm working on that. Going to fire the bike up again in the morning - the valves on the right side were about 0.002" out, and the ones on the left - well, let's just say I'm starting to get worried about worn cam followers. Seems to be most of the way adjusted out. It was WAY out before, so we'll see. I'll get another video tomorrow.
1978 CX500 motor + 1980 CX500C frame
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10-07-2009, 9:05 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Sorry, no video - but the bike sounds MUCH quieter now! I'm going to go for a spin around the parking lot on it tomorrow, if the weather co-operates!
1978 CX500 motor + 1980 CX500C frame
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10-07-2009, 9:08 PM
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nathanfowler
Joined on 06-15-2009
Woodstock, GA
Posts 12
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Very cool. Love seeing / hearing about the progress!
78 cx500
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10-08-2009, 9:09 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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10-09-2009, 6:23 PM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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Wow, what a difference. I ran my first CX with sraight pipes and H box, and I thought that was loud!!! See if the "humming" annoys you at 55Mph.
If you're still in control...You're not going fast enough.
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10-09-2009, 8:10 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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It won't for now - I've got the 100% stock exhaust on the bike at the moment. I tend to work on the bike a lot at night, so I didn't want to disturb the neighbors, lol!
I've got a new taillight/license plate bracket on order from Earl's in Ocala. That will be in next week!
1978 CX500 motor + 1980 CX500C frame
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10-11-2009, 10:00 AM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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10-11-2009, 3:48 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Fiberglass seat pan roughed in:
I'm trying to decide how to go about mounting the seat. I'm thinking I'll fiberglass a stock style lip up front, and drill the fiberglass on the sides to simply bolt into the stock location.
I'm concerned, however, with how strong the side would need to be to prevent cracking in that area. Perhaps if I fiberglass a steel washer in the hole's location?
1978 CX500 motor + 1980 CX500C frame
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10-11-2009, 3:58 PM
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Iron272
Joined on 06-18-2009
Eastern Pa
Posts 1,029
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![Cool [H]](http://choppercharles.com/cs/emoticons/emotion-11.gif)
Re: Doward's Build
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| Doward wrote: | Fiberglass seat pan roughed in:
I'm trying to decide how to go about mounting the seat. I'm thinking I'll fiberglass a stock style lip up front, and drill the fiberglass on the sides to simply bolt into the stock location.
I'm concerned, however, with how strong the side would need to be to prevent cracking in that area. Perhaps if I fiberglass a steel washer in the hole's location?
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If you are going to bolt the seat pan I may have a suggestion in the fiberglass at the point of the hole for the bolts insert a washer and fiberglass the washer in the mold. That will add strength to the mounting point so it shouldnt crack down the road.
Iron272 - AKA CHROME
Live Free
CX650c but is going to be my own (cx650interstate PARTIALLY DONE LOL)
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10-11-2009, 4:11 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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| Iron272 wrote: | | Doward wrote: | Fiberglass seat pan roughed in:
I'm trying to decide how to go about mounting the seat. I'm thinking I'll fiberglass a stock style lip up front, and drill the fiberglass on the sides to simply bolt into the stock location.
I'm concerned, however, with how strong the side would need to be to prevent cracking in that area. Perhaps if I fiberglass a steel washer in the hole's location?
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If you are going to bolt the seat pan I may have a suggestion in the fiberglass at the point of the hole for the bolts insert a washer and fiberglass the washer in the mold. That will add strength to the mounting point so it shouldnt crack down the road.
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Yep, that's more or less what I was thinking. I've got about 1/8" thick on the sides, I'll mark where the holes need to be, then fiberglass a steel washer in place, and do another 1/8" thick fiberglass matting.
1978 CX500 motor + 1980 CX500C frame
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10-11-2009, 4:30 PM
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Iron272
Joined on 06-18-2009
Eastern Pa
Posts 1,029
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![Wink [;)]](http://choppercharles.com/cs/emoticons/emotion-5.gif)
Re: Doward's Build
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| Doward wrote: | | Iron272 wrote: | | Doward wrote: | Fiberglass seat pan roughed in:
I'm trying to decide how to go about mounting the seat. I'm thinking I'll fiberglass a stock style lip up front, and drill the fiberglass on the sides to simply bolt into the stock location.
I'm concerned, however, with how strong the side would need to be to prevent cracking in that area. Perhaps if I fiberglass a steel washer in the hole's location?
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If you are going to bolt the seat pan I may have a suggestion in the fiberglass at the point of the hole for the bolts insert a washer and fiberglass the washer in the mold. That will add strength to the mounting point so it shouldnt crack down the road.
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Yep, that's more or less what I was thinking. I've got about 1/8" thick on the sides, I'll mark where the holes need to be, then fiberglass a steel washer in place, and do another 1/8" thick fiberglass matting.
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I am sure you already know but make that mat go atleast 6 inches eitherway of center of the hole that way the washer will not try to rip out , Well it will but with that distance of mesh either side it shouldnt. Think of it as the old trick of lacing your fingers verses not makes the grip stronger
Iron272 - AKA CHROME
Live Free
CX650c but is going to be my own (cx650interstate PARTIALLY DONE LOL)
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10-11-2009, 4:49 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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I'm planning to do the 2nd layer of fiberglass over the entire pan, just to ensure structural holding. I'm figuring that 1/4" of fiberglass should hold up fine as a seat pan.
In other news:
BRAND NEW 55 watt Halogen in a Composite 7" H4 Housing:
35 watt H4 HID in same 7" Composite H4 Housing:
The only problem is that my HID kit is not bi-xenon - so I lose high beam capability. I may upgrade that down the line, but we'll see how it works out first.
I should also mention that the flash went off in the first pic, and not the 2nd. I'll get more pics after I get my headlight housing.
1978 CX500 motor + 1980 CX500C frame
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10-11-2009, 5:16 PM
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Iron272
Joined on 06-18-2009
Eastern Pa
Posts 1,029
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Re: Doward's Build
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| Doward wrote: | I'm planning to do the 2nd layer of fiberglass over the entire pan, just to ensure structural holding. I'm figuring that 1/4" of fiberglass should hold up fine as a seat pan.
In other news:
BRAND NEW 55 watt Halogen in a Composite 7" H4 Housing:
35 watt H4 HID in same 7" Composite H4 Housing:
The only problem is that my HID kit is not bi-xenon - so I lose high beam capability. I may upgrade that down the line, but we'll see how it works out first.
I should also mention that the flash went off in the first pic, and not the 2nd. I'll get more pics after I get my headlight housing.
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You may think I am crazy but try a regular Sylvania sealed halogen bulb (Damn brain fart) cant think of the total name But anyway. I have one in my bike and love it!!! yes it is a car bulb but has lasted for about 5000 miles Just my 2 cents
Iron272 - AKA CHROME
Live Free
CX650c but is going to be my own (cx650interstate PARTIALLY DONE LOL)
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10-11-2009, 7:07 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Yep, I've used the Cool Blue (which are actually crystal white) bulbs - they work nice, but they are nothing compared to a nice HID setup!
1978 CX500 motor + 1980 CX500C frame
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10-16-2009, 1:30 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Alright, fiberglassed the 'fender washers' (lol, I love it) into the sides of the new seat pan. About to start doing some sanding on them, then prepping the front for the bladed insert under the tank.
1978 CX500 motor + 1980 CX500C frame
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10-17-2009, 10:28 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Alright! Here's an in-progress picture of the first 1/2" closed cell foam layer going on:
Here's a couple pics of how it's sitting right now - the foam's not completely molded yet (still got some small spots to touch up and fill). I've got a softer high density open cell foam going on (about 2" thick) then I'll be covering it in black marine grade vinyl.
This is the first seat I've ever done - I figure I gotta start somewhere! ;) Feel free to comment on the work thus far.
1978 CX500 motor + 1980 CX500C frame
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10-18-2009, 9:59 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Not as much free time as I wanted today, but I did get to finish gluing and buttoning up the foam around the edging:
1978 CX500 motor + 1980 CX500C frame
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10-18-2009, 11:03 PM
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FOWG
Joined on 05-24-2009
Woonsocket, RI
Posts 366
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I think you said you are new to bkes. Remember this is a 30 yr. old machine. The fuel tank could have an accumulation of rust inside. You should have a filter in your fuel line. That could save you aggravation down the road.
1982 GL500 Silver Wing
God wants us on motorcycles.
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10-19-2009, 1:07 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Ah, didn't mention that - I cleaned the mess out of the inside of the tank! I plan on completely sealing the inside of the tank when I pull it back off and powdercoat it (which will obviously be after it has all the gas removed!)
I found a small disc style fuel filter for a lawnmower that would fit, but I was worried about fuel flow through the filter? Don't want to starve the carbs.
1978 CX500 motor + 1980 CX500C frame
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10-23-2009, 9:18 AM
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Clumzi
Joined on 01-26-2009
Olympia Washington
Posts 636
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Inline fuel filter at Schucks around here was $3. The in tank filters are silly IMO. My advice is to put on inline between your petcock and carbs. If you don't want to look at it, use a little extra tubing and tuck it underneath the lip of the gas tank. That is what was suggested to me and has worked like a charm since. -nick
1979 CX Rat Sport
(EMGO pods, wrapped MAC 2in1, 90/130 re-jet, 18" rear wheel, 50 cal ammo cans, Viper cafe faring, $.97 rattle can flat black)
1987 Toyota Van (Whitey)
2002 Subaru Legacy GT (Spiffy)
Motorcycles should be black and dirty :)
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10-23-2009, 7:19 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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I don't mind being able to see it - makes for quick inspection ;) Got the filter in and working great. Tomorrow I'm picking up the brake light and the rest of the material to finish the seat - hopefully I'll be showing off my new seat this weekend!
1978 CX500 motor + 1980 CX500C frame
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11-09-2009, 10:35 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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So... it took a couple weekends, lol. I'm at the stage of actually wrapping the seat with the vinyl - I'll post pics tomorrow.
1978 CX500 motor + 1980 CX500C frame
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11-10-2009, 8:32 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Pictures!
The seat, fully foamed, awaiting marine-grade vinyl covering:
Speedometer pulled apart for cleaning / refurbishing:
Speedometer and Tachometer needles being re-painted:
Pic of the seat on the bike (and you can see the rear brake light installed now):
Here you can see the light cups painted flat black, the '78 nacelle painted Charcoal Metallic, and the gauge cover done in flat black:
Chrome Duplicolor paint inside the bucket to help with reflecting the light:
Close-up of the formerly cracked/broken gauge cluster cover. It's not perfect, but it's good enough for me!:
Front Fender primed up and ready for paint:
I'll have more pics after I finish refurbing the gauges.
1978 CX500 motor + 1980 CX500C frame
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11-10-2009, 9:40 PM
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midgtmn
Joined on 02-19-2009
Rochester, NY - USA
Posts 285
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Looking great!
Do you have a tutorial or guide you are working off for doing the upholstering? I'd like to see how it was done in detail! 
'78 CX500 - Back from the brink!
'81 CX500C- Finally Running thanks to Ignitech!
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11-10-2009, 9:59 PM
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achille
Joined on 05-18-2009
Northwest coast,USA
Posts 271
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Looking good,more pix!
< TN
1980 CX500 D - resurrected
1978 CX500 #200752* - parts
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11-10-2009, 10:26 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Nope, I just did it from scratch.
Here's what I did (sorry for the lack of pics!):
1) Took everything off the bike, left the rear fender and the tank
2) Used cardboard to give me a small gap so I wouldn't suffocate the CDI box ;)
3) Used painters tape to cover everything off, nice and tight over the cardboard
4) Waxed the tape with regular Turtle Wax
5) Soaked my fiberglass matting and went to work with it!
6) After I had my fiberglass seat pan done, I put 1/2" high density closed cell foam over it, then 2" of high density foam that I cut/grinded into the basic seat shape I wanted, with a 1/2" of high density foam covering to smooth it all out. Next is covering it with the vinyl, as soon as I get a chance to!
If you guys / gals have any questions on how I did anything, just shoot ;)
1978 CX500 motor + 1980 CX500C frame
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11-10-2009, 11:27 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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Gauges refinished - put a set of 1893 bulbs in for the gauges, gonna test that out tomorrow evening sometime, see how the lighting looks.
1978 CX500 motor + 1980 CX500C frame
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11-11-2009, 7:25 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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And now with bulbs! MUCH better than what I had before, that's for certain!
These are normal bulbs, with the battery sitting at only 11.27volts, so they will be even brighter in action, with the bike running, I know.
Oh, random note - going to be putting a K03 turbocharger on the bike. Thinking 6 or 7 psi of blow-through CV carb action will hasten the CX's ability to get moving in a hurry. Picking up the turbo on Saturday. The turbo should spool (with a small enough housing) around 3500rpm and hold nicely until redline. The turbo can supply 270cfm of air, so this actually should be a good match with the CX.
1978 CX500 motor + 1980 CX500C frame
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11-13-2009, 11:34 AM
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Silent-Knight
Joined on 05-28-2009
Hartford, CT
Posts 111
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Can't wait to see how that turbo works out.
1979 CX500 C - a work in progress
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11-13-2009, 2:59 PM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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Not sure how you would go with compression ratio. May need 2 head gaskets.
If you're still in control...You're not going fast enough.
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11-13-2009, 6:06 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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| BearCX wrote: | Not sure how you would go with compression ratio. May need 2 head gaskets.
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NO! I can NOT be any more emphatic about that - you RUIN the quench area that Honda built into these combustion chambers doing that.
They run fine with 10:1 compression on 87 octane, so there is headroom in there. Running 93 octane with 5-7psi of boost should provide a nice midrange kick.
Now, if I get silly, I can have Probe Industries build me a custom set of 8.5:1 or so compression forged pistons, then I'll go with 20 or so psi.
I think the low boost / high compression combination will be more effective on the street, though. I want to avoid the problem that the original CX500T had - being a dog when off boost.
1978 CX500 motor + 1980 CX500C frame
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11-13-2009, 6:09 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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| Silent-Knight wrote: | Can't wait to see how that turbo works out.
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Picking up the turbo tomorrow, then I'll start mocking it up over the weekend. Well, I'm fixing a stuck injector on an STI tomorrow, so maybe Sunday. Ugh, I need more free time!
1978 CX500 motor + 1980 CX500C frame
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11-13-2009, 6:29 PM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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No disrespect, Doward. I see you have thought it through. Best of luck. Pics if ya can get some.
If you're still in control...You're not going fast enough.
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11-13-2009, 7:16 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Doward,
Getting more interesting, keep it up.
If you get a moment, tell us
1. How you'll handle the exhaust down stream of the turbo,
2. Where you'll mount the turbo and wastegate,
3. Any mods to the carbs to handle higher pressure / higher volume air flow going through (perhaps later cx650 35mm carbs with accelerator pumps?), and lastly
4. Ignition mods to fire under greater pressure.
I don't think any of these are show stoppers, just details to sort out.
BTW, did you ever consider a small supercharger instead? Down under and in the Far east, there were some small superchargers used on small displacement engines that might match up well with out 500cc's.
If you get this to work out, you may have to consider the cx650 clutch basket swap out to lower the RPM a bit since you will have more HP.
Good luck - and don't forget the pics!
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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11-13-2009, 7:31 PM
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Doward
Joined on 05-11-2008
Alachua, FL
Posts 814
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| BearCX wrote: | No disrespect, Doward. I see you have thought it through. Best of luck. Pics if ya can get some.
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Oh, no disrespect taken at all! I'm just.... emphatic when it comes to messing around on the engineering side of things ;)
| Spacetiger wrote: | Doward,
Getting more interesting, keep it up.
If you get a moment, tell us
1. How you'll handle the exhaust down stream of the turbo,
2. Where you'll mount the turbo and wastegate,
3. Any mods to the carbs to handle higher pressure / higher volume air flow going through (perhaps later cx650 35mm carbs with accelerator pumps?), and lastly
4. Ignition mods to fire under greater pressure.
I don't think any of these are show stoppers, just details to sort out.
BTW, did you ever consider a small supercharger instead? Down under and in the Far east, there were some small superchargers used on small displacement engines that might match up well with out 500cc's.
If you get this to work out, you may have to consider the cx650 clutch basket swap out to lower the RPM a bit since you will have more HP.
Good luck - and don't forget the pics!
Jerry |
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1) I'm looking at 2 x 1.5" piping from the head to the turbo, and a single 2.25" exit from the turbo. I haven't mocked up where the piping will run just yet.
2) I haven't mocked it up - I have two designs I'll try first:
a) Mount the turbo similarly to the stock CX500T - aka across the front of the bike. Advantages: low center of gravity, balanced perpendicular to the plane of the bike (front to rear). Disadvantages: Oil return will most likely require a pump.
OR
b) Mount the turbo in-line with the plane of the bike on one side. Advantages: Oil return can definitely be gravity fed. Disadvantages: 30-40lbs of metal hanging on one side of the bike.
3) I'll be using the stock carbs. The difficult part will be bringing the turbo air outlet up to the carbs. I'm going to replace the stock airbox with a fabricated surge tank, that will have a single inlet from the turbo, and work just like the stock airbox in regards to air flow into the carbs. The only thing I'll need to add will be running a line from this 'surge box' to the fuel overflow of each carb to keep the fuel bowls' pressure differential even.
Naturally, I'll be rejetting the secondary jet to something a little bigger ;)
4) No mods planned aside from ensuring plenty of good, clean connections between all of the ignition components. I do think the Ignitech will be a significant upgrade down the line, though!
If this works out, I intend to replace the CX500 engine with a CX650 engine, and build from there with the turbo system ;)
I never considered a supercharger system, as I have yet to find a supercharger for $50, lol
*edit* BTW - anyone know the stock connecting rod length for the CX500 and CX650, as well as the turbo models?
1978 CX500 motor + 1980 CX500C frame
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