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Project CeXy - CX500

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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 14:13 - 19 Jun 2017    Post subject: Project CeXy - CX500 Reply with quote

My Dad has had his CX500 from new, it is a 1981 'B' model. He got it a year to the day before he married my mum. This Bike has carried him and mum all over Europe and was the first bike I ever went pillion on. it obviously has a fair bit of sentimental value to the family. Around the bike we moved to where mum and dad still are it developed a misfire, i'd guess this was about 1997-2000. Dad did some diagnosis and determined it was something to do with the ignition set up.

This bike has a fairly complicated stator as I understand it, so is fairly prone to going tits up. It is also an engine out job to fix. He looked to strip the bike but fell at the first hurdle. One of the Engine bolts has a strange semi captive nut arrangement. This was stuck, he is a bit foggy about what happened (getting old Laughing ) but he thinks a piece of engine casing that held the nut broke off He got it off in the end but drilling a hole in the nut and getting a pin in place to hold it (no room for a spanner.)

Anyway after this he lost heart with it I think and it sat there for years. Fast forward to 2005 and I got my first bike soon to be followed by him buying his '99 Sprint. The CX has just sat there (in the way!) with a blanket over it for years.

http://img.photobucket.com/albums/v295/chris-red/IMG_20170606_185343_zpseix92cpt.jpg

Fast forward again to a couple of years ago this happened.

I really enjoyed it I love working on broken bikes and getting them going again. Trouble is I have 3 already and no money or space to get my own.

Since then I have been 'threatening' to do the same to the CX500. He kept putting it off and putting it off. After doing some research last year I came across this. It is an ECU that doesn't require half the full functionality the stator that the standard CDI does. It is also programmable and just generally more reliable by all accounts. I told dad about it and he seemed a bit more interested in sorting something. This year he brought it up a few times as something he wouldn't mind doing so I started looking at it again. A couple of weeks ago I looked more into the Ignitech and as a coincidence noticed a post by WD Forte about CX500s. I can't remember what the post was but it gave the impression he very clued up on CXs. I fired off a PM and he was very helpful! He sent me a link to a diagram he had made which helped me to determine if the ignitech would run the bike as is.

http://i39.photobucket.com/albums/e164/napalmfire/statortest.jpg


WD Forte wrote:
Worst case scenario for you is a faulty pulser
that's pins 1-2 and 4-6

3-7 you can live without if they're dodgy, Ignitech doesn't use them

8-9 are the source coils which an Ignitech doesn't need either.


Nervously I took my meter out to the garage...

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170617_135427_zpsogomelzl.jpg

5/1 108
5/2 92
5/3 208
5/4 111
5/6 92
5/7 207
5/8 5500
5/9 305
8/9 5300


Cool

Good news, Ignitech will solve the ignition issues. Laughing

A told dad and he seemed pretty chuffed, we order the parts the day after.

I went round to have a look at all the bits after they have been delivered to make sure everything was there, and was surprised to see dad has already gotten started.
[img]
http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170617_134116_zpslmbsgdep.jpg[/img]

He said he was just cleaning up little bits as he went like the battery tray. (He will likely remove it and paint it)

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170617_135415_zpsh8ssfkzb.jpg

Believe it or not, this lot (including the non pictured battery) cost the best part of 400!

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170617_135544_zpsd7ovnck9.jpg

This should be all that is needed (barring fluids) to get the old girl running. On top of what is pictured it needs a new front tyre and maybe new discs and pads. Although I'm hoping we can get the discs skimmed as new do not seem available!

I'm hoping to pop round tomorrow to test fit the ignitech and strip the carbs.

This will be a general tidy up and get running. The bike is in pretty good shape it just needs a clean and a thorough going through.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 14:35 - 19 Jun 2017    Post subject: Reply with quote

One this I was fairly pleased with, I noticed on Wemoto they sold rubbers for panel/tank mounting etc. I checked with dad and he was missing one so ordered it from WM it was only 1.50 ish turns out it was a genuine part! Was surprised by that.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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Oldie
Traffic Copper



Joined: 05 Dec 2010
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PostPosted: 16:45 - 19 Jun 2017    Post subject: Reply with quote

Nice base bike. I had the black one until a mate in Ireland wanted it. Still have a Eurosport and it's a great feeling riding a CX, well once you get decent tyres fitted!

Looking forward to your reports.
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kgm
Crazy Courier



Joined: 04 Jun 2015
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PostPosted: 18:49 - 19 Jun 2017    Post subject: Reply with quote

I'm nearly finished my black A model. You've just reminded me of another expense I'd forgotten about. Spent way too much on the rebuild. Just as well mine was inherited also!
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 15:19 - 20 Jun 2017    Post subject: Reply with quote

Dad just called, he's been working on it today. I'm suprised he has really delved into this. I thought I would be doing the bulk of the work.

Bad news is the swingarm apparently has some large holes in it. I'll see about getting it welded up and powder coated.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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WD Forte
World Chat Champion



Joined: 17 Jun 2010
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PostPosted: 16:53 - 20 Jun 2017    Post subject: Reply with quote

chris-red wrote:

Bad news is the swingarm apparently has some large holes in it. I'll see about getting it welded up and powder coated.


Swinging arm rot is not uncommon on a CX I've repaired quite a few.
Don't powder coat it after repair that's a waste of time and money
because they rot from inside out the same as the lower frame around the engine hangers ( repaired there a lot too)

Here's my recipe for a 'we love you long time' swinging arm
After removal cut away the rot on the centre cross section part
then drill a 6-8mm hole in the void into the LH leg tube

Jig or brace the SA legs apart before welding
otherwise the welding process /heat can pull the legs together making wheel fitment and removal ferkin hard work

After its repaired and painted pour old engine oil/waxoyl derustoprene whatever, down the LH leg to flood the centre cross member
sloosh it about with gusto then drain most of it out

It'll be good for years after that, my current one was done in 2005
and still sound.
I do similar around the engine hangers using strategically placed holes I can get the ACF50 Nozzle in and squish it in every 6 months or so
____________________
1979 cx500 - Zanussi Wd12: - LG Combi Multiwave - Swan 4 slice toaster with removable crumb tray
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kgm
Crazy Courier



Joined: 04 Jun 2015
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PostPosted: 17:06 - 20 Jun 2017    Post subject: Reply with quote

WD Forte wrote:

It'll be good for years after that, my current one was done in 2005
and still sound.
I do similar around the engine hangers using strategically placed holes I can get the ACF50 Nozzle in and squish it in every 6 months or so


My technique also. Mine us still on the original swing arm and it's pretty solid amazingly
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 21:02 - 20 Jun 2017    Post subject: Reply with quote

I went round to strip the carbs and have a look at his progress.

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_192618_zps5iikp6kv.jpg

Old boy did well especially in the heat!

Swingarm looks pretty nasty!

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_192625_zpskjcmw2bb.jpg

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_192656_zpsugeldoni.jpg

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_192647_zpsolqclrrg.jpg


I set about the carbs they look fairly clean on the outside although the inside is varnish central. I stripped them half down, unfortunately almost 40 year old JIS screws don't always play ball especially when you use the 'wrong' screw driver. Before shagging them totally I though I'd better get the proper tools so have just ordered a set of jis drivers.

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_192712_zpsfvzag4pl.jpg

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_201743_zpstndumg6o.jpg


I bunged what I could in the US cleaner.
http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_201813_zps0jtffp6z.jpg

Any idea how to remove the needles? There seems to be a plastic sleeve holding it in Confused I didn't want to force it for fear of damaging it. I've undone the flat head in

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170620_201752_zps4k5tnsbt.jpg
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 21:05 - 20 Jun 2017    Post subject: Reply with quote

Anyone have any experience with these patten ones?

http://www.davidsilverspares.co.uk/CX500-1978/part_227465/

Wondering if this will be better/easier/cheaper than fixing the old one.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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WD Forte
World Chat Champion



Joined: 17 Jun 2010
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PostPosted: 22:06 - 20 Jun 2017    Post subject: Reply with quote

I wouldn't get too obsessive about the carb needles and jets unless they're badly worn.
I've never had to change a set yet.
What I would be looking closely at from experience, is the over flow tubes in the float bowl.
These have been known to rot, split and leak
I used 3/32nd" brass tube from a model shop and JB Weld to repair mine.

The air cut of valve diaphragms split for a pastime.
As an experiment, I blocked mine off years ago and had no ill effects

SA:
You won't get much change from 200 quid for a new one plus postage
so buy if your not happy/able to weld it yourself
I'd check for possible water ingress though, it may be fine for few years but then start to rot inside like the originals otherwise.


Finally, as I suggested in the PM
You really want know the condition of the cam chain.
CX cam chains are best changed sooner rather than later
____________________
1979 cx500 - Zanussi Wd12: - LG Combi Multiwave - Swan 4 slice toaster with removable crumb tray
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Oldie
Traffic Copper



Joined: 05 Dec 2010
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PostPosted: 05:51 - 21 Jun 2017    Post subject: Reply with quote

For general maintenance tips, have a look at the Rob Davis site.

http://robdavistelford.co.uk/webspace/cx500/
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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 06:41 - 30 Jun 2017    Post subject: Reply with quote

Tiny bit of progress, I finished splitting the carbs, JIS drivers are amazing, I would never consider touching an 80's Jap bikes carbs without a set.

It undid all screws without any real trouble. I had butchered one of the screws slightly using a Phillips, even with the JIS drivers I wasn't convinced I could undo it. In the end I peened the screw head this pushed all the churned up metal where it had started to round back into place. I was surprised how well it worked, it almost looked new. They it came straight out with the JIS.

I left the bits for dad to ultrasonically clean.

http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170629_200525_zpsetzggeml.jpg


He took the exhaust off too and it is in OK shape! I was surprised by that. He said it came off really easily too. Next step is to remove the swingarm, clean it up and assess the rot.

Parts Pile is getting bigger.


http://img.photobucket.com/albums/v295/chris-red/Mobile%20Uploads/IMG_20170629_200545_zpsd8fldfpo.jpg
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.
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View user's profile Send private message You must be logged in to rate posts
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