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CX Customization and Modifications
Started by Spacetiger at 08-06-2009 5:56 PM. Topic has 65 replies.
  
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 08-06-2009, 5:56 PM
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Spacetiger
 
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Enough of the parts have trickled in to start the project. One step forward, two back seems to be how this will go.
The most important part to come in was the wheel. I got a 82 CB 900 Custom wheel (2.5 x 16) that looked to be a good swap out choice. The CB 900 Custom had the swing arm with rear drive on same side as the CX/GL500, and the disc on the left.
The only concern was how the CX/GL rear drive would match up with the new wheel. After dropping out the stock wheel and removing the rear drive, I did a fit check with the rear drive on both wheels. It fits!
Next, I put the new wheel and rear drive back in place. It all fits.
Problems encountered:
The stock axle may not work and I need different spacer and bushings. I also found out the rear caliper I got is for the wrong bike (I needed a 900 Custom caliper, they sent a 900F which mounts to the wrong side).
Bright side:
Although the wheel worked, I have decided to change wheels. I will complete the modification to get everything done, but have decided to upgrade to a 80/81 GL 1100 wheel because it is 2.5 x 17". This should drop the engine RPM's about 6.3%.
As I make meaningful progress, I post updates and when finished a complete parts list used and pictures.
Enjoy
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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08-06-2009, 6:34 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Right side - a bit out of focus, will post a better pic as the project progresses.
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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08-06-2009, 7:35 PM
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Huck369
Joined on 07-14-2009
Somerset, KY
Posts 86
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Re: 82 GL 500I: Rear Disc modification
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Interesting project....
Huck
1983 Honda CX650 Custom
2005 Honda CRF250X
1990 Honda VTR250
1984 Honda Ascot VT500
1996 Honda VLX 600 Shadow
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08-10-2009, 5:47 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Parts are slow to trickle in, so updates are slow too.
Today the 80 CB 900 Custom axle (and spacer) arrived. The CB 900 Custom and GL 1100 use the same axle. It’s clear it is bigger to handle the extra HP. I would not be surprised to know its the same as the one on the CX 500 turbo. The thick end of the axle is the same diameter...
I'm still waiting for 3 more "small" parts so I can complete the bike. So far, nothing looks like it will be a show stopper but is slow!
Here is a pic of the axles side by side. The caliper bracket is below the CB 900 axle. The shinny hole at the end is the end the axle goes through. There is no way to use the CX/GL axle.
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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08-10-2009, 5:48 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 wheel, disc, and caliper bracket held together with the axle. You cannot see the spacer between the wheel and bracket but it is critical. It fits into the wheel and provides the correct spacer so the bracket base is correctly spaced to the disc. The bracket can easily spin about the disc without rubbing.
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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08-10-2009, 5:49 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a side shot so you can see the spacer lip.
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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08-11-2009, 4:11 AM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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Re: 82 GL 500I: Rear Disc modification (Update)
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Pardon the dumb question, what stops the bracket from spinning round and round? 
If you're still in control...You're not going fast enough.
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08-11-2009, 7:06 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update)
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The caliper bracket has a attachment at the top for for a brace that attaches to the swing arm - similar to the drum brake which is on the bottom. When the caliper squeezes the disc, the disc tries to push the caliper counter clockwise. The brace prevents this.
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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08-11-2009, 8:20 AM
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MikeCMP
Joined on 05-27-2009
Chardon, Ohio
Posts 354
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Re: 82 GL 500I: Rear Disc modification (Update)
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Is there a bearing on the caliper bracket where is contacts the axle?
Are you modifying the swing arm for the pivot stop and to enlarge the holes for the CB axle?
Looks good so far - I am trying to collect the parts for the front disc mod that you did so I can do it to my CX - these threads are very informative!
Mike
1979 CX500 Custom
My first bike and loving it!
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08-11-2009, 1:43 PM
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Panther
Joined on 05-09-2006
Las Vegas, NV
Posts 1,264
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Re: 82 GL 500I: Rear Disc modification (Update)
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Also....
 Spacetigers signature wrote: |
66 BMW R 50/2 "scary to ride"
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Really? How so?
Peace & Light
>^..^<
..........
'83 GL650swi "My Little Grey Lady"
'82 GL500swi parts bike
'78 DT175
'86 LS650 Milady's bike
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08-11-2009, 2:38 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update)
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You could use the rear master cylinder; it would be a bit
harder to integrate in because of the mounting points. I did have a bid
on one in eBay, but lost it because it got too expensive and I didn't want to
bid to win. I had to watch how expensive the project was becoming; I had
made a decision to go with a 17" wheel. This required me to get a
new tire, etc. Because of this, I decided to reduce costs were I
could. The master cyclinder and reservoir were parts that allowed leeway
where as the wheel, caliper, brackets were must have to fit the Gl500.
The R50/2 was scary to ride because it was so underpowered and under braked it
was difficult to keep up with busy city traffic and the stopping distances were
LONG. I didn't ride the bike very much but it was cool to look at.
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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08-12-2009, 5:55 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update #2
The 17” wheel came in today. I got home late from work, so I was limited in what I could do. I was anxious to know if I’d still have good clearance, so I wanted to at least complete the fit check tonight. 2 good news bits from the fit check: 1) There is about ¾” space between the front of the swing arm and tire, and 2) the Dunlop tire is in really good condition – I’m going to clean it up good and pass on getting a new tire until next season.
So now, only 2 parts left to come in, the GL 1100 final drive unit and the replacement rear caliper. I decided to not turn the CB 900 Custom axle down on the end so I could reuse the GL 500 final drive. The reason - cost. I could get a GL 1100 rear-end for 9.99 + shipping. This allows me to retain a stronger axle + if I ever had a problem on the road, I could repair it using stock parts. If I had a lathe, I would have turned down the axle. The cost to have a machine shop do it was more than the GL 1100 rear-end. The rear caliper should come in Thursday or Friday.
The next step will be to pull the swing arm so I can fabricate the mounting point for the brace attaching the top of the caliper bracket to the swing arm (this is the end I have to work on). Having the swing arm will make this easier to do, so this will be Thursday’s task.
Here is a pic of the new wheel on the bike. The larger wheel makes the disc look “normal” sized. The disc – same size as the front discs – made the 16” wheel look small. You can see the brace attached to the top of the caliper bracket.
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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08-12-2009, 5:56 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 master cylinder and reservoir. You can see the two mounting points. With the swing arm out, I’ll have better access to fabricate a mounting bracket to integrate it into the current rear brake linkage.
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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08-13-2009, 6:34 AM
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jhovel
Joined on 01-02-2008
Near Bendigo, Australia
Posts 69
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Re: 82 GL 500I: Rear Disc modification (Update 2)
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Brilliant research and trial-and-error deduction!
I'll follow this thread with great interest.
I noted that you are planning to use a stainless steel bolt to anchor the brake reaction rod. Please use a high tensile bolt instead! It's a "Jesus Bolt" (if it breaks you may go to Jesus). Stainless steel gives no visible warning when it lets go and is forbidden in critical location like this in countries where engineers inform the engineering laws instead of bureaucrats - like Germany....
If you can get a proper anchor mount welded on, that would be even safer, as it doesn't transmit all the force through a bolt, but pushes against a steel bracket.
Also, I believe the CX500EC and CX650ED rear axle would fit this rear end. It may be the correct length for your swing arm - the GL1100 rear axle may be too long.
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08-13-2009, 10:29 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update 2)
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Thanks for the info on the SS bolt - thats what I was going to use.
As for the axle, it will work even though it is a different length. you can see this in the shading in the pic where the axles are side by side.
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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08-13-2009, 9:35 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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The caliper arrived. Mounted up the caliper; nothing like a factory fit. Now for my hack job…
I started to remove the swing arm, I‘ll need to do this to get a good fabrication on the brace anchor point on the swing arm. My plan is to run a bolt into the swing arm. If I can weld a nut to the underside via the left swing arm hole – great. If not, I’ll run the bolt all the way through the swing arm and put a nut on the underside. The diameter of the bolt will be larger than the bolt attached to the caliper bracket, so if there is a question which side will fail first, it should be the caliper end. Thanks jhovel on the heads up concerning the Jesus bolt.
Got the left side muffler off, but no luck on the lock nut on the swing arm. Tried a few things including heating it up, but its on tight! I plan on getting the proper tool (socket) to get it of Friday. Meanwhile, I started looking into how I’ll mount the rear master cylinder and reservoir.
Looks like I can cut about 1.5” off the plunger end of the master cylinder and mount it via a bracket just behind the starter where I can mount a brace to the frame. The key will be to get it aligned so I can integrate the master cylinder plunger with the existing braking system. The current brake system has the pedal on the right actuating a shaft. On the left side of the bike, the shaft has a arm attached to a 3 foot long ¼” steel rod that runs to the drum brake arm (you can see it hanging down near the bottom of the wheel in the pic below). I plan on removing the long steel rod, flip the pivoting attachment mounted on the arm and mount it to the plunger. This way when I press the brake pedal, the arm will compress the plunger on the left side of the bike… A pic will help clarify this. Perhaps I’ll get one up on Sat. The reservoir will go somewhere aft on the left side or on the right side under the carburetor. I’ll decide once I get the master cylinder in.
Here is the latest pic of the caliper on the bike. I’ll look into how well it works before deciding to rebuild it or not. It came in very good condition. I washed the wheel after taking this pic, I really lucked out getting a really good tire on the wheel for $21.50 + shipping – the tire looks almost new. It’s a Dunlop like my current front tire
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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08-14-2009, 7:25 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 4
I’m trying to get the master cylinder installed and the anchor bolt on the swing arm done this weekend. I figured the final dive will not get here until Monday or Tuesday, so I shouldn’t be rushed to get this done.
I was hoping I could get the swing arm off the bike to clear up room to get the bracket mounted. No luck getting the lock nut free. I do not have the special 3/8 socket tool – poor planning on my part! After several tries to get it off to include a butane torch to heat it up, it is still on. I will see what I can do short of getting this off. I did call the local Honda dealer; they do not stock it, but can order it for $55 and can get it in 4 days! You can get them on eBay for $8… I’ll try Saturday to get everything done without pulling the swing arm… We will see.
Here is a side picture of the proposed mounting location of the master cylinder. After removal of the 3 foot drum brake rod, you can see the arm attached to the shaft (left side of bike) that the foot pedal is attached (right side of bike). By removing the brake pedal, you can rotate the shaft and move the arm a little over 90 degrees clockwise. The master cylinder is attached to the arm in the picture. I think all I need is a simple square tubing to mount the master cylinder to and then screw the tubing to the inside of the frame. I fear I will need to get the swing arm out of the way, but we shall see tomorrow.
If I get the master cylinder mounted tomorrow, the bolt will be easy on Sunday…
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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08-14-2009, 7:26 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a picture of the rear of the master cylinder. It is not held against the frame so it leans over and looks like it may get hit by the swing arm. I did check and there should be sufficient clearance once it is all mounted up.
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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08-14-2009, 8:51 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,838
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Re: 82 GL 500I: Rear Disc modification (Update 4)
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This is getting pretty creative. You better finish it because I'm adding it to the quick list. When done list exactly what parts were needed to do the job and follow that up with a later update on how it works.
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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08-14-2009, 10:52 PM
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Panther
Joined on 05-09-2006
Las Vegas, NV
Posts 1,264
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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| Spacetiger wrote: |
I started to remove the swing arm, I‘ll need to do this to get a good fabrication on the brace anchor point on the swing arm. My plan is to run a bolt into the swing arm. If I can weld a nut to the underside via the left swing arm hole – great. If not, I’ll run the bolt all the way through the swing arm and put a nut on the underside. The diameter of the bolt will be larger than the bolt attached to the caliper bracket, so if there is a question which side will fail first, it should be the caliper end. |
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So, the first caliper bracket was for the right side and would not mount over the disc and connect to the support rod.
But why couldn't you just slide the bracket around and point it at the ground, then the rod could go into the original stay for the drum brake? This would require you to loosen the axle and disconnect the rod, then slide it upright when you are bleeding the brakes, but it wont affect operation while upside down.
Peace & Light
>^..^<
..........
'83 GL650swi "My Little Grey Lady"
'82 GL500swi parts bike
'78 DT175
'86 LS650 Milady's bike
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08-14-2009, 11:07 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,838
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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A suction brake bleeder tool would fix that.
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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08-15-2009, 5:44 AM
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BearCX
Joined on 03-11-2008
Roseworthy, Sth Aust
Posts 525
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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If you drill the swing arm all the way thru', you may want to fit a "crush tube" the same width as the swing arm. This will stop the hollow tube from gradually squashing, and releasing the tension on the bolt. Or use a Nyloc nut/shakeproof/Glenloch/Loctite etc etc...
Just a thought.
...and as Joe said, "stay away from Stainless" High tensile is made for just these applications. But will rust if not painted.
If you're still in control...You're not going fast enough.
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08-15-2009, 6:01 AM
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jhovel
Joined on 01-02-2008
Near Bendigo, Australia
Posts 69
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Just a quick one: High tensile bolts and nuts are available in a zinc plated finsh ('blue'=silver, 'yellow'=gold and black passivated). All are rust proof.
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08-15-2009, 7:00 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Panther,
The caliper bracket was designed for a left side brake caliper. There is no way to use the right side caliper; 1) bolt holes do not line up (one is thicker than the other) and 2) the brake pad would not line up to the disc.
With the correct caliper, I did investigate mounting the caliper upside down so I could use the drum brake arm. Several problems: 1) the brace is different on both ends, so I would have to modify brace, caliper bracket, and/or swing arm. 2) the caliper has to rotate CW about 240 degrees and almost contacts the swing arm from the underside.. It has to rotate this far because the caliper bracket (see previous picture of it by the axles) attachment point on top is biased to the front. and 3) it sits very low to the ground. What really made me give up this idea was point #2 above. The caliper bracket/caliper assembly is free to rotate about the disc because the swing arm (as part of the suspension) goes up and down. By fixing the brace at the top of the caliper bracket when the swing arm goes up, the brace pushes the caliper assembly CW. When the swing arm goes down, the caliper assembly rotates CCW. You do not want the brake to bind up within the tolerance of the swing arm.
Blindstitch
I will include:
1. Complete parts list in final update. They will look like:
Part………………Bike Source……………...Bike Bandit
Final Drive………82 GL 1100……………...n/a
Axle……………...80 CB 900 Custom……...147398-001
Collar…………….80 CB 900 Custom……...145846-001
2. Post riding feedback on how it brakes using just the rear brake and when used with the new larger brakes up front
3. Some curves on the lowered RPM vs speed for the different gears .
BearCX,
Will use a crush tube on the swing arm.
Jhovel,
I got the (yellow) grade 8 bolts yesterday. They are like the bolts you see on the monoshock (color) so it does not look out of place.
All keeping up on this thread,
Appearance question for all. I am trying to figure out a mounting scheme for the rear master cylinder. What do you think about drilling 2 small holes (1/4”) through the frame (near the swing arm - not the tubing) and mounting bolts through them (also using crush tubing) to hold the fabricated master cylinder bracket? I have to repaint this part of the frame and would paint the bolt head black too.
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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08-15-2009, 10:07 AM
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Clumzi
Joined on 01-26-2009
Olympia Washington
Posts 635
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Not sure if this has been asked or addressed yet, but could something like this be designed to work in conjunction with the rear drum or is that not feasible/more work than its worth? -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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08-15-2009, 11:35 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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??
Do you mean have a disc and drum brake?
I think the disc is more than enough rear braking. If there is one worry - it is too much brake ability and will lock up the rear 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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08-15-2009, 4:05 PM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,838
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Food for thought. The front brakes control 75% of the braking. Why? The caliper and disc brake.
The rear controls 25% and it's drum brakes.
A rear disc would be and advantage as long as it doesn't lock up. That's where the rider has to adjust it right or learn how much to push.
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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08-15-2009, 4:45 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 5
I ran around a lot in town on Saturday trying to get the tool to take the swing arm off. No luck. The Honda dealers don’t carry tools for bikes over 10 years old. They were not a lot of help when I told them it was for a 1982 bike… I also tried all of the auto stores.
So I decided to go ahead and drill the two holes in the side to mount the master cylinder. I figured the 6mm holes would not be a problem as long as I got them right and didn’t have to make them bigger. I’ll run spacers on the other side of the frame to master cylinder to get a solid tie to the frame. As it is, it is snug and I cannot move it. There is about a ½” gap to close.
Tomorrow, I’ll fabricate a mount for the reservoir – probably to the left side of the bike. I will also drill the brace hole in the swing arm and relocate the regulator/rectifier that was hanging under the battery cage (you can see the mounting bracket in the picture). I’ll move it to the other side of the battery cage.
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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08-16-2009, 1:49 AM
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jhovel
Joined on 01-02-2008
Near Bendigo, Australia
Posts 69
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Blindstich: the reason 75% of braking is controlled by the front is not BECAUSE they are disk brakes, its because when braking 75% or more of the bike's weight is on the front tyre. Any more than 25% breaking force on the rear wheels and they stop and skid....
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08-16-2009, 5:59 AM
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jhovel
Joined on 01-02-2008
Near Bendigo, Australia
Posts 69
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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Oops, I might have misinterpreted what Blindstich was trying to say.....
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08-16-2009, 7:28 AM
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Blindstitch
Joined on 03-14-2009
Greenfield Wisconsin
Posts 9,838
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Re: 82 GL 500I: Rear Disc modification (Update 3)
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That's about it.
On four wheels i'm willing to skid around but on two is deadly.
I don't even want to imagine how bad drum brakes up front would be. On the other hand I do wish I had a right disc. Seems like the american cx and gl500 got the short end of the stick.
1979 CX500 Supertanker
ATGATT makes riding a bike like a sled easier.
Quick Reference
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08-16-2009, 7:37 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 6
A short update, will post more info at the end of the day. Here are some pics of the effort planned for today.
Get the swing arm to caliper brace bolt in place.
Get the brake reservoir in place – It now looks like it will go in on the right side under the side cover. If I have time, I’ll get some hose to hook up the reservoir to master cylinder.
Relocate the regulator/rectifier.
Cut the lawn, trim the bushes, wash the cars, help clean the house, go to dinner… The other duties I have been neglecting. :-o
Here is a side pic with the wheel in place. The brake hose is WAY too long, but will work for now.
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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08-16-2009, 7:38 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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This is the planned location of the reservoir, no other clean spot for it. Unless there is a leak (obvious sign will be fluid on the bike and floor). I figured I can keep an eye out on the pad thickness as a sign on how much fluid is left. Otherwise, its pop the cover off at the beginning and end of riding season to check things out. This shouldn’t be too much added stress on the side cover.
Can someone tell me how to post more than 1 pic at a time?
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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08-16-2009, 6:51 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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It’s tight, but the regulator/rectifier is relocated a few inches over. It took far more time to remove the battery tray so I could drill out the welds holding the regulator/rectifier bracket. I had to remove the air box, monoshock, and starter to get at all the bolts! After all the measuring, I got it put back together and find I only have a few mm's clearance in a couple of spots. But everything is firm, so I don’t think vibration will cause me a problem. The brake and reservoir lines can make it to the master cylinder.
Late this afternoon, I got the reservoir in - it’s a solid connection to the air box, but since I had to pull it to get to the regulator/rectifier relocation there is no picture tonight.
Everything is in a mess, will put things back together tomorrow night. Just waiting for the new final drive to button everything up; if it comes in tomorrow I can get it put back together Wed night.
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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08-17-2009, 7:20 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 7
Remember when I said this was a two step forward, one back kind of project? Can you guess what steps were taken today?
I got home and the last part was on the door steps – the GL 1100 final drive is here at last. After a quick change of clothing, I spent the next 3 hours in the garage….
After opening the package, I quickly realized the gear interface to the driveshaft is different, very different. I could see some other subtle differences on the wheel interface side. Uh-oh. I rechecked the CX/GL 500 final drive to GL 1100 wheel, no problem, its just that the GL 1100 (and CB 900) final drive is more stout because it has to handle almost twice the HP. It also clear I cannot use this as a straight bolt in replacement.
So, after looking it over, I decide to take apart the GL 1100 final drive. It only cost 9.99 + shipping, so what the heck. It took about 45 min to take it apart. That included heating the housing with a butane torch to be able to unscrew the retainer so I could take out the pinion gear.
I get dinner and sit on the computer studying the GL 500 final drive. I find that they use the same bearing on one end, so I get to thinking, just reuse the GL 500 pinion gear and bearing and cap on the other end mated to the GL 100 housing and ring gear… So I spend another 45 min taking apart the GL 500 final drive. After I get the pinion gear out I look at both and realize… its not going to work unless I spend some serious time getting new bearings that have the race to fit the GL 1100 case but bearings to fit the GL 500 pinion gear shaft. Possible, but a lot more work to include sourcing shim rings too.
So, I am defaulting to plan B - have the last few inches of the CB 900 Custom axle (the part that will have to go through the GL 500 final drive) turned down and rethreaded to use the GL500 axle nut. Of course, this assumes I didn’t screw up my final drive, if so; I’ll just get another one off eBay. That should take me another week.
I’ll look for a machine shop to do the axle work tomorrow. Perhaps I can get everything together by this Saturday? We shall see. Here is the pic of the night, a comparison of the pinion gears.
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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08-17-2009, 10:03 PM
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ChopperCharles
Joined on 02-18-2006
Chapel Hill, NC
Posts 613
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Re: 82 GL 500I: Rear Disc modification (Update 6)
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Why not use the CX500 axle, and replace the wheel bearings in the CB750 wheel with CX wheel bearings? Then make a spacer to fit between the axle and caliper bracket to make up for the lost diameter?
Charles.
87 TW200 (STOLEN! Help me find it!)
93 EX500 Ninja Street Fighter Project
84 V65 Magna (daily rider)
75 GL1000 (in pieces)
79 CX500 Deluxe Street Fighter Project
81 GL500 Interstate Restoration Project
Location: Durham, NC
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08-18-2009, 3:20 AM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Charles,
I figured it would take a good machinist 30 min to put the axle in a lathe and reduce the axle thickness a few mm (match the CX/GL 500 axle) on the final drive side and re thread it. It would take me far more time to try and match up new bearings + have a special bushing made to fit the caliper bracket. I would also have to mod the CX/GL 500 axle on the thick end.
Here is a pic of the work planned.
Jerry
[ Edit update 1100hrs Tues 18 Aug: Just dropped off the axle at the machine shop. Not a problem to get the effort done, but cannot get to it until Monday, available Tuesday... 1.5 hrs @ $90/hr... ]
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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08-18-2009, 4:34 PM
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Panther
Joined on 05-09-2006
Las Vegas, NV
Posts 1,264
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Re: 82 GL 500I: Rear Disc modification (Update 6)
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did you remember to allow a little extra space in the area to be machined to tighten the assembly after install?
The system is designed to tighten against all the pieces on the axle, not the axle it self.
Peace & Light
>^..^<
..........
'83 GL650swi "My Little Grey Lady"
'82 GL500swi parts bike
'78 DT175
'86 LS650 Milady's bike
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08-18-2009, 4:43 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Re: 82 GL 500I: Rear Disc modification (Update 6)
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Panther,
The short answer is yes.
All of the pieces hat will be on the axle (washer, caliper bracket, bushing, wheel, final drive, and nut) have been accounted for - or, I think they have.
When I get the axle back, I will know in 15 min, because it doesn't take long to put everything together. In fact, the bike should be ridable perhaps as early as late Tuesday next week.
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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08-23-2009, 4:54 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 8
The machine shop called late Friday to say they were done with the axle… and I was not home from taking my daughter to college. They closed at 5 and do not open until Monday – so it was clean everything up weekend waiting for Monday.
I got 3 things done this weekend.
1. Resolved how to arrange the rear brake return spring so it works with the master cylinder. I JB weld 4 fender washers to the tab of the spring and rotated it about 180 degrees so the tab that used to go in a hole in the frame at about the 6 o’clock position is now rotated clockwise at the 12 o’clock position – see the pic below.
2. Got the final drive back together. What a pain it was coming apart – it was worse putting it back together.
3. Put all the pieces back on the bike in anticipation of the axle. I couldn’t believe how much I had to take off to get at the interior of the bike for mounting the master cylinder (crash bars, entire exhaust, battery, batter try, air box, shock, rear inner fender…). It’s all back on except the inner fender. I’m leaving it off so I can measure then drill the mounting bolt for the caliper brace.
I’m looking at how to best mount the HD mufflers. Yes, I have decided to go with the deeper sounding pipes. Will post how this goes under a different posting when done.
Here is the pic of the spring
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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08-23-2009, 4:55 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 master cylinder, it’s tight, but everything fits with some margin. The return spring has a nice feel on the brake pedal. The total travel is about 1.5“down, but I suspect it will not go that far when I get brake fluid in the system.
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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08-23-2009, 4:56 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 brake reservoir mounted behind the air box.
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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08-23-2009, 4:58 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a side shot of the bike with all the bits back on. I’m looking at what level to hang the HD mufflers.
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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08-24-2009, 6:28 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Update # 9
Not too much done today, but got the axle, so I can mount everything up.
Here is a picture of the axles side by side so you can see the machine work on the axle on the bottom in the picture. Gary machined the last few inches to match the CX/GL axle and rethread the end so I can use the CX/GL nut. Cost was $143.10
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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08-24-2009, 6:29 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a picture of the inside of the final drive so you can see the collar the axle slides in.
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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08-24-2009, 6:30 PM
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Spacetiger
Joined on 05-16-2009
Chantilly, VA
Posts 1,353
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Here is a picture of the old axle in the final drive. Note how our axle, on the left side, slides almost flush with the swing arm. The thick portion of the old axle becomes part of the spacer, even so, we have a small bushing that closes the gap to the drum brake cover.
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... » Re: 82 GL 500I: Rear Disc modification (Update 4)
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