Honda CX500 & GL500 Forum

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02-08-2010, 1:05 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: gl 1100 wheel no flange_web.JPG Here is a pic of the GL 1100 wheel. You can see the center of the wheel has 3 different lips (diameters). . 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!)    Report

02-08-2010, 1:07 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: gl 1000 wheel no flange_web.JPG The GL 1000 wheel is similar – see pic, but has different depth dimensions. So the only way to solve this is to trim 3/10” on the backside of the flange and 3/10" from the second lip on the axle. This will allow the flange to sit further back and with the 2nd lip not in the way, the final drive can slide closer to the wheel. I’m sure this is as clear as mud. With any luck, the machine shop will be open tomorrow. I'll have them trim the flange, 2nd lip on the wheel, and since they have the wheel mounted up, I'll have them turn the center hub of the wheel so the cage from the final drive fits into the wheel, Yes, I know, this isn't clear either. Once the work is done, I'll point out what was done. I'm sure my wallet will be much lighter after I pick up the parts. 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!)    Report

02-08-2010, 1:48 PM AggieGL650 Joined on 10-26-2008 Fort Worth, TX Posts 111 Re: GL650I vs. GL500I fork Jerry - this all looks really good and is very interesting to watch it all come together. Back to your questions from page 1, I don't know what type of fork that I would upgrade to if I ever do it, but I was considering a later model sport bike. Not sure how well that would work out, especially with my desire to go with wire wheels and a more classic look. That's where multiple bikes come in... :). As cool as those new brakes look, I can guranatee that I won't be spending $1000 (or anywhere close) for any parts on this bike. 1983 GL650 cafe in progress 2002 Suzuki SV650 (Ol ' Yeller)    Report

02-08-2010, 3:59 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork and the best part is it doesn't cost a dime... Until it's your turn in the barrel. Did you explore this site? http://www.randakks.com/gal.htm You can see some interesting wire wheels and excellent brakes. The other web site I posted earlier has some interesting modern inverted forks with wirewheels. If you searching for a different fork setup cross reference a head bearing kit for the CX650 model with other Honda bikes - especially the ones with inverted forks. When you find a match (both use the same kit), then you know the bike frame does not need to be modified. You just have to make sure you get the tripple tree, forks, and brake components. If the wife does not allow me to get another bike, I will continue projects on this bike. ONe of them will be wire wheels. I think of them as another pair od shoes for my bike. I have a pair now, and with any luck 2 pairs by next week. My sport coat will be another project... 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!)    Report

02-08-2010, 9:32 PM Panther Joined on 05-09-2006 Las Vegas, NV Posts 1,264 Re: GL650I vs. GL500I fork If either of you guys have some of those "spoke conversion" plates made up. I'm in for a set or three. (well, for the rear. I would need them for the front.) Peace & Light >^..^< .......... '83 GL650swi "My Little Grey Lady" '82 GL500swi parts bike '78 DT175 '86 LS650 Milady's bike    Report

02-09-2010, 6:16 AM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Panther, What do you mean with the term spoke conversion plates? In Germany, some CX riders have the comstar wheel taken apart then machined the hub so they can accept spokes and then build the wheel. There are machined pieces that go on both sides near the hub - is this what you are refering to Panther? 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!)    Report

02-09-2010, 9:49 AM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Well, the bike tasks for today are done. I rechecked all wheel/biike dimensions and took the wheels, axle, and final drive to the machine shop. Here is their info if you are nearby. They do nice work. Craig is the guy I deal with. RBM Machine, LLC 44964 Underwood Lane Sterling, VA (703) 435-3276 I explained what I needed done and why. Craig checked everything out and said they could do all three things. I'll explain it all using pics once I get the wheel back. In order to get the wheel done, I had to demount the rear tire. Like a fool, I came home to try... after 10 minutes in the cold, it became very clear I did not have the right tools. The best tool I had was a $20 bill in my wallet. Lucky for me, there is this place called Hard Core Choppers right next door to the machine shop. I called and they said they could demount the tire if I brought it down before the snow came today. I went there, and they took the wheel and let me walk around back to look at the bikes while the only mechanic took care of the tire. Some pretty impressive bikes. They do all there own custom work from the smaller pieces to include making their own wheels from wheel billets. There must have been 20-40 bikes there! As I was walking around getting the guided tour, I kept looking back at the guy demounting the tire on the special machine. It was clear I made the right choice, as there was no way I could do what the machine did in 15 min. Nothing like having the right tool for the job. After the tire was off, I walked next door to the machine shop and dropped off everything. Turns out the shops are only about 9 miles from my house. It should be done next week. We get Monday off, so I hop I can get it Monday. 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!)    Report

02-09-2010, 2:44 PM Panther Joined on 05-09-2006 Las Vegas, NV Posts 1,264 Re: GL650I vs. GL500I fork  Spacetiger wrote: Panther, What do you mean with the term spoke conversion plates? In Germany, some CX riders have the comstar wheel taken apart then machined the hub so they can accept spokes and then build the wheel. There are machined pieces that go on both sides near the hub - is this what you are refering to Panther? Jerry Yes, those are the plates. As I remember them, they where two plates per hub that had been drilled and chamfired for spokes on the outer rim and holes on the inner to mount with the stock comstar "spoke" bolts. I do not believe any machine work was needed on the Hubs. Peace & Light >^..^< .......... '83 GL650swi "My Little Grey Lady" '82 GL500swi parts bike '78 DT175 '86 LS650 Milady's bike    Report

02-09-2010, 5:21 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Panther, I thought that's what you ment. If I were to do spoke wheels, I'd find a way to make the GL 1000 wheels work. I started a thread on spoke wheels. I hope someone trys to make them work given all the modified CX/GL's we see on this site. The spoke wheels would look cool. If no one trys, I may take a stab at doing a set. I thought about how to get around needing a machine shop but don't know if it is doable yet... 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!)    Report

02-11-2010, 8:33 PM greghoro Joined on 08-14-2008 Wheaton, IL Posts 75 Re: GL650I vs. GL500I fork Some GL1100 (Aspencade) had vented brake rotors. Would these work? Are the calipers different to accept the what I would assume to be a thicker rotor? 1982 GL500 (self converted to Interstate)    Report

02-12-2010, 3:26 AM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: vented disc 2a.jpg greghoro, I don't know. The last year model for the CBX also used vented disc brakes - see pic. If they fit and they look like they might, I think it would be over kill for the anything but the turbo bikes. I think they would look good on them! 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!)    Report

02-13-2010, 4:06 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: hex bolt_web.JPG Time to get some of the rebuilding underway; today was the forks and calipers... Took the forks off the bike to do this but before removal, I used the triple tree to hold the stanchions while loosening the top caps. This prevents damaging the stanchions. Once of, I slide each fork out and drain oil. There didn’t seem to be enough oil in each leg – wish I had measured ho much was in each leg, oh well. In removing the hex bolts, I had to keep the leg from rotating. I didn’t want to use the a clamp – worried about marring the legs, so here is how I held the fork leg from rotating while removing the hex bolt. 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!)    Report

02-13-2010, 4:07 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: fork disassembled.JPG This worked one side… the other side had a hex bolt locked tight and it went bad. $%it. To get it out, I had to drill the head out. In addition, the C-ring broke, it was rusted a bit so that and the hex bolt made things a bit harder to take the fork apart. It took longer, but everything did come apart. I will have to go to the Honda dealer this Monday to get another hex bolt and 2 new C-rings. It took only a few minutes to get the 2 pistons out of the right calipers. I used compressed air to get them out. I plan to re-sand the fork lowers, left caliper, and clean up the front wheel. I’ll then replace the bearings in the front wheel then polish them on Sunday. Monday, I’ll get the other parts and reassemble the forks, calipers, and hopefully mount up the tire and wheel. If I’m lucky I can get the front assembly put back togher Monday night. 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!)    Report

02-13-2010, 6:56 PM Blindstitch Joined on 03-14-2009 Greenfield Wisconsin Posts 9,863 Re: GL650I vs. GL500I fork In case you need to know this is what it says about fork oil in the manual. 83 Gl650 Front Fork Oil Capacity is 275cc (9.3oz) ATF after disassembly 1979 CX500 Supertanker ATGATT makes riding a bike like a sled easier. Quick Reference    Report

02-13-2010, 7:15 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Thanks Blindstich, forgot the 650 forks held less oil than the 500's. But, I thought we were going with 20wt [fork] oil vs ATF? volume would be the same though. 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!)    Report

02-13-2010, 7:28 PM Blindstitch Joined on 03-14-2009 Greenfield Wisconsin Posts 9,863 Re: GL650I vs. GL500I fork  Spacetiger wrote: Thanks Blindstich, forgot the 650 forks held less oil than the 500's. But, I thought we were going with 20wt [fork] oil vs ATF? volume would be the same though. Jerry Well I don't know what you're going with but I'm going with 20wt BelRay Fork Oil. 1979 CX500 Supertanker ATGATT makes riding a bike like a sled easier. Quick Reference    Report

02-14-2010, 7:01 AM AggieGL650 Joined on 10-26-2008 Fort Worth, TX Posts 111 Re: GL650I vs. GL500I fork Looks great, Jerry. I nearly had similar issues breaking mine down, but somehow managed to break it loose when I thought that all may be lost. Excellent job of laying everything out. I'd do that, too, but I've run out of room with the entire bike torn down, so I'm using the 1,000 labeled zip lock bags method.' By the way, the spray stripper you recommended is perfect. Oddly enough, it's the same brand as the paint on gel I've been using, but does work much better. I've got caliper and bracket nearly complete (just need to work on the nooks/crannies a bit) and one more to go. Jeff 1983 GL650 cafe in progress 2002 Suzuki SV650 (Ol ' Yeller)    Report

02-15-2010, 1:55 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: polished bits_web.JPG Thanks Jeff. I see you are making progress too. The calipers are a PITA. Mine are "good enough". I'll wait to get it all back together before I try to polish any more. Its lunch break now; here is an update where the effort stands…. behind schedule seems to be the correct phrase. I was hoping to have the calipers and forks polished and back together today. I was hoping to get the front wheel polished too. I’ll be lucky to get the polishing done today. Here is the progress so far… 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!)    Report

02-15-2010, 1:58 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: lower fork minus tab_web.JPG The fork is slowed due to the broken 50mm Circlip. Went to the local Honda dealer hoping this is a stock item – “no sir, I can order for you, be here about Thursday…” So I ordered it and bought the fork oil. I came home to finish sanding and polishing the forks… I find out I needed the little stub on the fork to keep the speedometer box assembly from rotating… Seems I had the machine shop mill that off when they worked the fork. So, I will have to fabricate a stop; perhaps a job for JB Weld put on a couple of pins in the fork(?) - clearly a job for later today. The machine shop called and said the wheel was done. A quick dash out to pick up the wheel… Seems the machinist forgot to double check his work. Another .05” is required to come off the drive flange on the teeth side. Otherwise, the other work was done correctly, everything matched up within .05". When you take out the drive flange and mount up the final drive to just the wheel, everything is dimensionally good. This means spoke wheels using the GL 1000 are possible… This is a pic of the lower fork that will need to be modified with a new tab on the end. The tab for the 83 speedometer box is different than the tab for 81/82 speedometer box. Had I left the 83 tab on, it would not have worked… 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!)    Report

02-15-2010, 5:36 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: speed box vs needed tab_web.JPG Here is how the speed box lines up with the fork. . 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!)    Report

02-15-2010, 5:37 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: pop rivet in fork_web.JPG Here is the pop rivet in the fork. I used a little JB weld to hold the pop rivet. I figured the SS pin in the rivet is enough to keep the speed bok from rotating. If not, I will drill a little bigger hole, tap it and run a SS hex head bolt in with a lock nut. 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!)    Report

02-15-2010, 5:38 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: wheel in progress 1_web.JPG Worked on the polishing the wheel. Its not coming out as shinny as I thought it should. I will sand it again tomorrow and try a harder compound when polishing the rim. I figured the spokes are steel so they will not polish up like the rims… I should be able to get the rear wheel tomorrow and post a pick of it mounted but not cleaned. A pic of the wheel [edit: the flash of the pic is making the wheel rim look more shinny than it 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!)    Report

02-15-2010, 6:22 PM AggieGL650 Joined on 10-26-2008 Fort Worth, TX Posts 111 Re: GL650I vs. GL500I fork Nice work, Jerry. I don't get as much (any, really) work done during the week. Just too much going on. 1983 GL650 cafe in progress 2002 Suzuki SV650 (Ol ' Yeller)    Report

02-17-2010, 6:27 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: gl 1000 wheel_web.JPG I picked up the rear GL 1000 wheel and it looks like its going to work out nicely. Here are some pics to show the machine work and explanations on what was done. For the wheel, I had 2 things done. I had the second tier lip around the bearing machined back 0.31”. You can see the grinding marks from the bit as it went around the center part of the wheel. The second thing I had done to the wheel was machining the inside of the outer ring of the hub. I had enough so the dust shield from the GL 500 final drive can fit easily in the center like it does for the GL 500 and GL 1100 wheel. See pic 1 of 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!)    Report

02-17-2010, 6:29 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: mounted wheel right_web.JPG The next piece machined was the drive flange. I had 0.26” taken off the back (max amount) and 0.05” taken off the front. The total amount taken off equals the amount taken off the 2nd axle lip… So, the math says it should all fit together, but it doesn’t. I still have a 0.05” (thickness of the washer) mounting clearance issue. I will have to research this bit to see where the problem is. Here are some pics of the rear wheel mounted without the drive flange in place. The final drive and wheel are mated without the drive flange. In this configuration, there is no clearance problem. Pic 2 is the drive side, you can see the dust shield in place, no clerance issues. 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!)    Report

02-17-2010, 6:30 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: mounted wheel left_web.JPG Pic 3 shows the rear disc on left side. The wheel and disc needs to be cleaned up A quick check indicates the brake disc aligns with the brake caliper bracket – yes! 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!)    Report

02-17-2010, 6:30 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: wheel centered_web.JPG Pic 4 is the back; you can see the wheel is [almost] centered. So, this effort shows the ComStar GL 1000 wheel can be modified to work with the CX/GL final drive. I suspect the GL 1000 spoke wheel can work too but will have to be done a little differently to accommodate the dust shield. From the pics of the spoke wheel, it’s not clear there is enough material to remove from the inner hub to accommodate the GL 500 dust cap. In this case, I think you will have to cut the dust shield to make it just wide enough to leave a small gap to the wire 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!)    Report

02-20-2010, 12:23 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 1 pre assembly_web.JPG Looks like a good day to try and make some measurable progress. I gathered the parts and set up camp in the kitchen to reassemble the forks. I had to promise, no damage and a clean-up afterwards… After sanding (800 grit) down and polishing any nics in the stanchions I was ready to assemble the forks. Here is a pic of the preassembly stage. 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!)    Report

02-20-2010, 12:25 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 2 order of components_web.JPG Took awhile to get the first leg together (never did this before). I had to figure out using a caliper to measure the spacing/thickness of the three items that go on the stanchions when its in the fork lower. I had to get the orientation of the middle item right. Here is a pic of the orientation I used as the Haynes manual was useless. I used a 2 foot long 1 1/2” diameter PVC pipe to set the 3 individual items one at a time. Before tapping the seal into final place, I set the circlip in on top of the seal then reslip the PVC pipe on top. The seal was soooo tight, I actually did this a few times (take apart, reassemble) before the seal would seat all the way down. The second fork was a bit more stubborn so I had to the garage to tap against the concrete floor. . 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!)    Report

02-20-2010, 12:25 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 3 caps_web.JPG I then took the aircaps and cleaned and polished them before filling with oil. Here is a pic of 1 cap done, the other awaiting. . 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!)    Report

02-20-2010, 12:26 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 4 underside of cap_web.JPG There was a thread back about putting the fork oil in via the air inlet if you take out the air valve 1st. I don’t think this would work very well because the oil is pretty thick and the hole very small. Here is a pic of the underside of the cap so you can see the size of the hole. . 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!)    Report

02-20-2010, 12:27 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 5 finished forks_web.JPG After getting the oil in and air caps on, I wiped the forks down and took this pic. It’s now time to load up progress info while I eat lunch… . 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!)    Report

02-20-2010, 7:22 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 6 bike_web.JPG I’ve given up trying to mount the front tire stem… and tire. So, I concentrated on putting the front of the bike back together. Mounted the GL 1100 handlebars. They mounted up without a problem to include cable lengths. The only two things I had to change (as a result of the fork swap) was using the GL 650 brackets that hold the wire loom box to the stanchions and having to drill the ignition switch to accept larger diameter screws (the GL 650 triple tree top uses larger diameter screws). It’s starting to look like my old bike. 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!)    Report

02-20-2010, 7:22 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 7 front pic_web.JPG Here is a front shot of the wheel/brakes. . 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!)    Report

02-20-2010, 7:23 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 8_stock MC_web.JPG Here is a pic of the original MC (with 14mm piston). Note the brake line attaches to the front of the MC. . 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!)    Report

02-20-2010, 7:25 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 10 SZ MC_web.JPG Here is a pic of the Suzuki GS450 MC (with 12.7mm piston). The brake line attaches to the side of the MC. I’ll use this one to see what difference there is. If it’s what I’m looking for, I’ll keep an eye out for another one with slightly larger reservoir. 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!)    Report

02-21-2010, 6:30 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 1. bike with GL1000 wheels_web.JPG Last day of the weekend to make any meaningful progress. Here’s how she sits… . 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!)    Report

02-21-2010, 6:32 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 2. trimed piece_web.JPG I plan to have the tires mounted to the wheels – but, before committing the $’s, I need to know I can get these wheels to work. The front is good to go, it’s the rear that still has a small problem. There still is a spacing problem getting the rear wheel and everything matched up to fit between the swing-arm with the wheel centered; it’s about 0.05” off to the left. After getting sufficiently dirty checking and rechecking everything, I am convinced, I need to have this amount taken off the front of the drive flange. If I take it to the machine shop it will cost me about 3 days waiting and 1 hour of labor to do the work…. There has to be another way, so I figured I’d try to cut off the end with a hack saw. It can’t be that hard can it??? I set a washer the right thickness on the table holding an ice pick and rotate the drive flange face down to scribe a line all the way around. Then I get my workmate bench and my best hack saw ready with a new blade (24) in…. 2 hours later its off – see pick… LOL, it worked. . 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!)    Report

02-21-2010, 6:33 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 3. left side rear wheel mounted_web.JPG I mount up everything, it did the trick. I’ll do a little more sanding, but its 95% done. Here is a pic of the left side with the axle tightened 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!)    Report

02-21-2010, 6:33 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 4. rear wheel centered_web.JPG Here is a pic of the back, she is centered up with all the pieces in place. I have a little work to modify the 6 drive flange studs, but that can wait. I will try to get the wheels and tires and have them mounted up by Tuesday. . 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!)    Report

02-21-2010, 6:35 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 5. awaiting tire mounting_web.JPG Here is how she’ll sit until about Wed or Thursday. . 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!)    Report

02-21-2010, 6:38 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 78 cx 500 rear wheel.jpg In case someone was wondering what the CX500 ComStar rear wheel looked like, here you go. The [5 stud] drive flange is very different from the GL 1000 wheel. The GL 500 wheel is the same as the reverse ComStar wheel used in 81 up, thats why you can swap the rear wheel within the GL 500 family. 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!)    Report

02-24-2010, 5:36 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: gl 1100 wheels on bike_web.JPG Wednesday is here and the tires on mounted. Here are the GL 1100 wheels on the bike (before). This is probably the last time they will be on the bike... . 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!)    Report

02-24-2010, 5:37 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: gl 1000 wheels on bike_web.JPG Here are the GL 1000 wheels on the bike (after)… It looks like I was hoping. There is still much to do, but I think I can start to think about the light of the tunnel and ignore the sound of the train’s whistle. 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!)    Report

02-24-2010, 5:42 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: left view gl 1000 wheel_web.JPG Left view of the wheel. Still have to work the drive flange studs, clean wheel, remove paint from caliper, bracket, clean disc, then polish wheel, caliper, and bracket... After that it's SS brake lines... Then all the other projects so the bike is ridable! 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!)    Report

02-25-2010, 4:50 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: fender on_web.JPG Going out of town this week to next Tuesday, so there will be NO progress made until Wednesday... :-( Just bolted up the front fender. I was not sure how it would line up since the fork is a bit wider + the small metal fork brace under the fender was not removed. I found 2 of the 4 bolts holding it on and used them. Looks like it will not be an issue. See you all 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!)    Report

03-07-2010, 6:50 PM Spacetiger Joined on 05-16-2009 Chantilly, VA Posts 1,353 Re: GL650I vs. GL500I fork Attachment: 80% bike_web.JPG Well, except for the wrong brake caliper kits preventing the front brakes from being completed... And I haven't finished the final drive preventing me from riding.... The bike is done. I'll consider the front fork swap complete, but will complete the 2 items above and post under an older thread. I'll only post riding impressions when I'm able to take her out. Here is how she sits in the garage. 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!)    Report

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