1980 CX 500 Café Racer Build
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Thread: 1980 CX 500 Café Racer Build

  1. #1
    Senior Member Mike's Avatar
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    1980 CX 500 Café Racer Build

    Index to this Thead
    Numbers correspond to the page numbers.




    1. Intro to the Form!

    2. Tear Down
    Cylinder Replacement, Carb Cleaning
    CBR600RR Front End Swap, Finding Muck in the Engine

    3. Triple Bypass
    Simple Tach Holder

    4. Electrical Fan Up-Grade
    Installed Cam Chain Guide

    5. Wont Start
    Stator Pick-ups Reversed

    6. CX500 to CBR600RR Controls Rewired Right Side
    CBR600RR Gas Cap Rekeyed to original CX500 Key

    7. Wiring Diagrams
    Left side conversion, Relay Wiring for Hi-Lo Beam
    Oil & Neutral Lights installed in Triple Tree Top

    8. USB Power Outlet installed
    Front Calipers Modified for GL1000 Spoked Wheels
    1st Under Mount Seat Pan

    9. New Headlight, Fan Electrical Diagram
    Radiator Temp Switch Install, Moved Electrical Under the Seat

    10. Under Mount Seat Pan Continued
    Failed Attempted Rear Sets

    11. Smaller Blinkers Installed
    Shortened Throttle Cables, Rear Brake Light Wiring
    Rear Set Tabs Made, Fuse Box Moved to Under the Seat

    12. Engine Name Plates Comped (Never Made)

    13. Tach Gauge Design
    Rear Brake Reservoir Bracket, 1st iPhone Holder Bracket

    14. MotionPro Cable End Link
    Started the Rear Wheel Conversion, Drilled Rotor (Ended up too Big)
    Hammerhead Shocks Fitted

    15. Rear Caliper Painted and Modified
    New Deluxe Tank

    16. Rear Set Tabs Continued
    Front Wheel Spacers

    17. Tank Mock Ups
    Started the Front Rotor Adapters

    18. Stripping Frame for some Welding
    Welding Rear Set Tabs, New Spokes
    New Cone Mufflers, Front Rotor Spacer Diagram

    19. Failed Rear Rotor Grinding
    CNC’ed Front Rotor Adapters
    Hammering Fork Indents in Tank

    20. CNC’ing Continued
    Front Fork Spacer Replaced
    Milling the Rear Rotor Smaller

    21. Rear Wheel Spacers & Caliper Bracket

    22. Rear Caliper Bracket Diagram, Removing the Un-Needed Frame Tabs
    Front Wheel/Rotor Spacers Installed, Front Wheel Spacers Diagram

    23. Rotor Hub Adapter Diagram

    24. Installing Murray’s Carbs
    Mounting Tires

    25. Mock Up of Bike

    26. First Ride After Rebuild
    Muffler Options & Baffles

    27. Baffle Discussion, CNC’ing Rear Bracket
    Deluxe Tank Frame Tabs, Ground thru Wires Repair

    28. More CNC Maching, Pink Foam Seat Mock Up
    Seat Shape Discussion, Rear Caliper Bracket Install (Had to be remade)

    29. Radiator Shroud Design

    30. Can’t Spell
    Brass Rod Mod, Tach Bracket Revisited

    31. Tach Bracket Finalized
    Baffles

    32. Baffles Installed
    New Under Seat Pan, Final Rear Caliper Bracket

    33. Under Seat Pan Finalized
    Dropped off Bike to Metal Fabricators
    Tach Face Plate Made
    Exhaust System Made
    Shifter Lever Made

    34. Muffler Routing & Finishing, Battery Tray
    Petrol Tank Rear Bracket Made, Tank Petrol Cap Installation

    35. Tail Section is Started
    Tank Cap Welded In
    Tail Light Installed

    36. Tail Section Almost Done
    Stupid Battlestar Comment
    Seat Pan Comps
    Bike Returns Home

    37. Final Frame Strip
    Cleaning Up Center Stand
    Final Frame Clean Up

    38. Disassemble Continues
    Rear Axle Spacers Finalized, Exhaust Wrap
    Rear Axel Spacers Diagram
    Painting Parts that Cannot Be Powder-coated, Rear Shocks Painted

    39. Tank/Cap Progress
    Polishing Engine Parts
    Lye removes Anodization

    40. Tank, Tail Seat Pan Getting Close to Being Finished
    Under Tail Cover Made, Final Under Mount Seat Pan Made, Radiator & Under Seat Pad Diagrams

    41. Battery Bracket Made, Parts Being Prep’ed for Powder Coat,
    Parts Being Prep’ed for Anodizing, Death Trap?

    42. Parts Dropped off to Powder Coaters
    Powder Coat Parts List

    43. Parts Back fro the Powder Coaters, Failed Radiator

    44. Assembly Starts

    45. Assembly Continues



    Start of Original Post

    I just picked up a 80 CX500 with 10,112 mile on the clock, it is a pretty clean bike one owner, 82 year old could/would no longer ride it. Did not have the heart to tell him I was going to chop it and make it a Café Racer. That said riding it home today it had a knocking in the engine and the oil seals need replacing.









    Last edited by Mike; 12-19-2014 at 05:37 PM. Reason: updating the links
    ScienceGuy, Ooobadaga and mpbrink like this.

    Perfectly Designed to Improve Your Performance

    1980 CX500RR

  2. #2
    Senior Member Stan in Toronto's Avatar
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    Its a real shame to sacrifice such a nice survivor to the chop.

    I like cafe racers, but I LOVE clean originals.

    It is yours to do with as you wish,but I see too many silk purses turned into pigs ears.

    If you are going to strip and chop, would it not be easier to use a barn find?

    Tons of CX owners would be thrilled to have an original in as nice a condition as yours.

    Just my opinion.

    Stan
    1980 CX500D (Gone but not forgotten)

    1984 CX650E (Gone to Kam's stable)

    1983 GL650i NOW the Daily Rider
    (yes Tom, finally)

    and
    A garage empty of parts bikes.

  3. #3
    Member ULTRA's Avatar
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    exactly what I think!
    thx
    spacetiger likes this.

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  5. #4
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    Quote Originally Posted by Stan in Toronto View Post
    I like cafe racers, but I LOVE clean originals.
    Stan
    Young boys LOVE cafe racer
    Old boys LOVE clean originals
    I Think You are in the age between.
    May i say midlife crisis ?
    Pelikaan likes this.

  6. #5
    Member eptapsyxos's Avatar
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    82 years old......

    if you reverse it you find my age.....

    i agree with the guys ///keep it clean its is outstanding condition

  7. #6
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    Quote Originally Posted by guelli02 View Post
    Stan
    Young boys LOVE cafe racer
    Old boys LOVE clean originals
    I Think You are in the age between.
    May i say midlife crisis ?
    Haha I agree there.
    1982 CX500c Bobber Build: http://cx500forum.com/forum/cx-custo...00b-build.html

    I have no idea what I'm doing lol.

  8. #7
    Senior Member Stan in Toronto's Avatar
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    Quote Originally Posted by guelli02 View Post
    Stan
    Young boys LOVE cafe racer
    Old boys LOVE clean originals
    I Think You are in the age between.
    May i say midlife crisis ?
    When I was a boy, cafe racers were in the future.

    The factory fresh look has always been my favourite.

    With so many different models available from different manufacturers, choice is available.

    There are some shining examples of gorgeous cafe bikes here and on other forums, BUT for every beauty I see there seems to be ten that look like the project lost funds or ambition part way thru.

    I have a bike that I could cafe and I plan to in the future. It will have to be within my mechanical and financial limits, and that holds me back.

    The drive to personalize our rides is different in all of us. I like that.

    I'm 61. If this is midlife, I didn't save enough to keep me & the bikes going.
    1980 CX500D (Gone but not forgotten)

    1984 CX650E (Gone to Kam's stable)

    1983 GL650i NOW the Daily Rider
    (yes Tom, finally)

    and
    A garage empty of parts bikes.

  9. #8
    Senior Member Mike's Avatar
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    I completely understand the "keep it original" thing. I have 12 vintage scooters in my collection, and some are all original and some are restored.

    I have the desire, time and funds to see this Café Racer though to the end. I never do anything half way.

    Thanks for you posts and comments. I just disagree with them and that is what make the world interesting. We all like different things.

    I want a CX500 Café Racer.
    Last edited by Mike; 12-19-2014 at 05:27 PM.

  10. #9
    Super Moderator granlund1's Avatar
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    Nicely done on the scooters!!

    As it's been said before - it is yours to do with as you wish.

    Do it to the best of your abilities - and PLEASE POST LOTS OF PICTURES HERE AS THE BUILD PROGRESSES!!!



    P.S. There are people here willing to offer help / advice and sometimes the unwanted comments.
    Last edited by granlund1; 09-01-2013 at 04:58 PM.
    zgoldwingman likes this.
    Steve
    1974 CB360 (sold)
    1979 CX500 Deluxe (sold)
    2006 ST1300

    Link to our WIKI (great tech info on the CX/GL)

  11. #10
    Senior Member Mike's Avatar
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    Just bought a 2008 CBR600RR front end suspension off eBay. In the collection stage.
    Last edited by Mike; 12-19-2014 at 05:28 PM.

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