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No.27 - 1981 Honda CX500

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blurredman
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PostPosted: 22:58 - 04 Apr 2015    Post subject: Reply with quote

Mine has the exact same oval pressure. I guess from where the cat has been sitting on it in the summer.. Laughing
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CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S.
Current: 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (bored to 295cc) - 38k, 1990 MZ ETZ251 - 49k, 1979 Suzuki TS185ER - 9k, 1972 MZ ES250/2 - 17k.
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Ted
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PostPosted: 00:10 - 05 Apr 2015    Post subject: Reply with quote

The cat eh? Wink


I forgot to say earlier, I double checked the mileage and its actually on 35k, not 65k... Which fits in with Blurredman's theory, perhaps this was a cherished bike!
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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blurredman
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PostPosted: 21:11 - 05 Apr 2015    Post subject: Reply with quote

Ted wrote:
perhaps this was a cherished bike!


Laughing
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CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S.
Current: 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (bored to 295cc) - 38k, 1990 MZ ETZ251 - 49k, 1979 Suzuki TS185ER - 9k, 1972 MZ ES250/2 - 17k.
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Ted
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PostPosted: 17:08 - 06 Apr 2015    Post subject: Reply with quote

I'm sure one of the previous 13 owners might have cherished it! ...like maybe the first one Laughing


Although I'm intending to address the mechanical and electrical aspects of the bike before anything else, I did end up doing some other work to it today...

The left grip has gone malleable and tacky, and every time I move it I end up with a sticky hand.

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/temporary_zpssyfq9arm.jpg


So I thought I better 'fix' it:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/temporary_zpswaglhuqk.jpg


Job done. Wink


The right grip is leather (or fake leather), not sure which is original, the other CX has foam ones fitted.
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Ted
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PostPosted: 17:15 - 06 Apr 2015    Post subject: Reply with quote

I just stumbled across £75 worth of parts I bought for the first CX back in 2008, but never fitted, including a cam chain and a lot of oil seals!
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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WD Forte
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PostPosted: 18:38 - 06 Apr 2015    Post subject: Reply with quote

Get a dental mirror and remove the bottle breather on the rear RH
engine case and have look at how much slot is visible on the adjuster
If you see more then 3-4mm, then personally I'd fit the new cam chain.
here's how
https://cx500forum.com/forum/attachments/technical-help-forum/5586d1382634071-cam-chain-adjuster-looks-50-50-me-what-do-you-guys-think-img_20131024_175116.jpg
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Ted
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PostPosted: 18:47 - 06 Apr 2015    Post subject: Reply with quote

Cheers, I'll have a look when I next roll it out!
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Ted
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PostPosted: 15:43 - 08 Apr 2015    Post subject: Reply with quote

I had another quick poke around a few bits. For some reason the two fuses below the ignition switch (labled as 10A) had been replaced with 15A and 20A fuses. I'm hoping the last guy just ran out of 10A ones...
I might have some old glass fuses laying around, if not I'll change them to spade fuses, maybe even mini-spades.

I undid the switches on the left handlebar, to address why the indicator switch only moved one way, and found a lump of broken plastic blocking the switch from moving the other way. No idea where the broken plastic is from, but I'm sure I'll find out.

The High/Low Beam switch is a bit strange... I was expected it to be a sealed switch, mounted into the switch housing. But it doesn't seem to be.
The actual white switch lever itself can be seen from the inside, and just seems to slide around, but when its all mounted on the handle bars the switch is difficult to move.

Is there somewhere online that has parts diagrams of the switch unit, just so I can figure out what has gone amiss?
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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WD Forte
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PostPosted: 17:39 - 08 Apr 2015    Post subject: Reply with quote

PITCHERZ!
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WD Forte
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PostPosted: 17:50 - 08 Apr 2015    Post subject: Reply with quote

As youre looking at the hilo switch when its on the bars
the switch assembly ( black with 3 solder joints)
should be top right and lined across the axis of the bars under where it says Hi-lights LO
It should have three cables
Blue white ( supply from RH bar light switch)
Blue ( out to high beam)
White ( out to low beam)

The button you see should move a wiper to bridge
blue/white to white
or
blue/white to blue
If you have the button only you'm buggered, start bodging

all the above is from distant memory so check for yourself to be sure
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Ted
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PostPosted: 12:24 - 12 Apr 2015    Post subject: Reply with quote

I've still not retured to the switches yet, but as it was nice weather yeatserday I rolled the CX out to do some work on the coolant system. I'm not impressed, it looks like much more work will be needed than I was hoping.


I removed the air box first, just to give myself more room to move. That was a bugger to get out, and I might be looking at ways to fit a cone style air filter, and have some tool storage space under there, rather than the big filter box. But that is for another day.

The battery / air box tray is nice and rotten:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_48_40_Pro_zpspxzqxouc.jpg


As far as the cooling system goes, there was a leak from the water pump casing:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_12_34_01_Pro_zpsymj2fseh.jpg


Upon removal of the coolant pipe, which I think had also leaked, existing fractures in the water pump housing became apparant, as it just disintegrated:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_19_06_Pro_zps7pupoxjv.jpg


Nice:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_19_13_Pro_zps7wc62ene.jpg


Sticky crustyness:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_19_22_Pro_zpscanjspmj.jpg


I removed the rad, this is on the bottom, I'm assuming its a drain plug, not really sure what to make of it...

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_21_28_Pro_zpsn7mhvynt.jpg


Then we have more signs of leakage from the thermostat housing, and associated pipework:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_14_26_33_Pro_zpscaxu4hs6.jpg


Brushed everything over, so should hopefully be able to spot new leaks:

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_15_00_59_Pro_zpsetbrgxcx.jpg


...but now I'm back to the 'loads of parts in a box' situation that I wanted to avoid... Sad

https://img.photobucket.com/albums/v474/EAM-Enterprises/Vehicles/Honda_CX500_2/WP_20150411_15_04_43_Pro_zpsvp6id50o.jpg


...Also, the N/S carb-to-cylinder rubber pipe has perished and split.

I'm hoping that the carbs will work as they are though, but I'm getting flashbacks of fuel pissing out and attempted rebuilding from the other CX...
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Ted
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PostPosted: 12:29 - 12 Apr 2015    Post subject: Reply with quote

I've got to check what O-rings I have got, but if I buy a generic O-ring selection pack, will they fit, or are these unusual shapes and thicknesses?


There was coolant in the rad and expansion bottle, rather than just water. The bike was stored where it got very cold in winter, and very hot in summer.
I'm not sure if the leaks on the coolant system were there prior to storage. I've also not seen coolant crystalise in that way before. Could it have expanded in the heat, in which case are there any areas I should check for leaks?
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Ted
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PostPosted: 18:28 - 12 Apr 2015    Post subject: Reply with quote

I found a bit of spare time today, and stripped the thermostat housing and pipes. The whole flipping lot was blocked up with instant gasket!

All the O-rings were flat and solid, and the two pipes are missing a few bits at the ends where they started to rot.

Took ages trying to clean up the parts, I'm not bothering with the outsides though, as looks don't bother me...
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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WD Forte
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PostPosted: 20:23 - 12 Apr 2015    Post subject: Reply with quote

Well that's definitely a cherished CX you got there
Bootiful patina on that, bootiful !
Just needs an oily rag running over it
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Ted
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PostPosted: 20:54 - 12 Apr 2015    Post subject: Reply with quote

Oh yeah, lovingly kept by all previous owners... Wink
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Ted
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PostPosted: 22:12 - 14 Apr 2015    Post subject: Reply with quote

FORTY-FIVE QUID FOR TWO PIPES & FOUR O-RINGS!!!!

...they can jog on! Where's that gutter sealant...?
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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WD Forte
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PostPosted: 12:20 - 15 Apr 2015    Post subject: Reply with quote

thermostat and pipes

https://www.ebay.co.uk/itm/honda-cx-500-thermostat-housing-/111508944640?pt=LH_DefaultDomain_3&hash=item19f6737700

https://www.ebay.co.uk/itm/HONDA-CX500-THERMOSTAT-HOUSING-AND-WATER-PIPES-/361213543955?pt=LH_DefaultDomain_3&hash=item541a014613

water pump cover

https://www.ebay.co.uk/itm/1912142-Honda-CX500-Water-Pump-Cover-Casing-/151551001946?pt=LH_DefaultDomain_3&hash=item234924c55a

Bearing Oil seals and O rings

https://www.simplybearings.co.uk
here's the cross reference list
https://i42.photobucket.com/albums/e315/sheppola/oringlist.jpg

rad plug from davidsilvers

https://www.davidsilverspares.co.uk/CX500B-1981/

CMSNL are pricey but the fiche is handy for info and part numbers

https://www.cmsnl.com/honda-cx500b-1981-england_model16473/partslist/
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Ted
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PostPosted: 19:35 - 15 Apr 2015    Post subject: Reply with quote

You are definitely the man to ask! Thank you.

I'll check the sizes against the selection packs, hopefully they're pretty standard sizes, as Silvers wanted £1.50 per O-ring for the thermostat pipes!

I'm watching that cover, but pondering if I should start raiding the spare engine, if the parts are any better, or try and leave that whole for a possible later engine rebuild and swap...

I'll have to dig it out I think.
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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WD Forte
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PostPosted: 20:01 - 15 Apr 2015    Post subject: Reply with quote

have PM'd you my number if you want any samaritans type phone support Laughing
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Ted
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PostPosted: 20:22 - 15 Apr 2015    Post subject: Reply with quote

Cheers! You may regret it when I'm up to my armpits in O-rings and miscellaneous Honda parts!
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Oldie
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PostPosted: 18:32 - 18 Apr 2015    Post subject: Reply with quote

All this CX talk - just had to go and get another one Mr. Green

Fairly tidy 500 Eurosport, which I've never really fancied, but the 4 hr ride home today got us well and truly bonded.

Re-sprayed, comfort seat, newish exhausts, good tyres and bar risers. Decent little bike. Much fun had today Very Happy

https://lh3.googleusercontent.com/-MxnWWp9YZoo/VS6sEdJsTMI/AAAAAAAAEjI/tsgHO7eRPEs/s800/%2524_86.JPG
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WD Forte
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PostPosted: 19:34 - 18 Apr 2015    Post subject: Reply with quote

Aha! the 'sports' version Laughing
Same engine as mine a TI.
None of the early CDI arseache

Out of curiosisty does the fuel gauge work properly?
never known one that did, but you never know
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Oldie
Brolly Dolly



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PostPosted: 19:54 - 18 Apr 2015    Post subject: Reply with quote

The fuel guage tried it's best for the first 50 miles after fill up but then quite quickly went back to it's natural habitat of nearly empty Very Happy

Unfortunately the trip meter is a bit precious too and doesn't like re-setting Laughing

All part of the charm.
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Ted
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PostPosted: 22:26 - 18 Apr 2015    Post subject: Reply with quote

Lol, my brother was looking at Eurosports on eBay earlier!

I'm still struggling to find a cheap way of purchasing O-rings, the sizes seem uncommon for selection packs, so going to have to throw some money at it. Sad

I've also decided to fetch the spare engine, rather than buy second hand bits.

I've got some photos to upload of attempted cleaning of parts, hopefully I'll get round to it tomorrow.

I was hoping to do more on it this weekend, but picked up an old Westwood garden tractor the other day, and need to tinker with that a bit...
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'07 Honda CBF500 / '93 Vauxhall Astra (www.fb.com/2wdOffRoader) / '04 Vauxhall Movano
Projects: '81 Honda CX500 x2 / '85 Land Rover One-Ten / ...plus many horticultural things.
||| Bike Test: DAS: PASSED 13/02/2009 ||| Car Test: PASSED 22/05/2005 |||
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Shaft
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PostPosted: 00:07 - 19 Apr 2015    Post subject: Reply with quote

Ted wrote:

I'm still struggling to find a cheap way of purchasing O-rings, the sizes seem uncommon for selection packs, so going to have to throw some money at it. Sad



If it's any consolation, I had the same problem when refurbing a Super Dream a few years ago - I run a garage, so I thought O rings would be the least of my problems, but everything I had was just the wrong size.

Luckily, it turned out the part I was using had been superceded and the O rings were no longer necessary, but if I had needed them, it was OE suppliers or nothing.
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