Fernweh CX500 SOE's cafe build
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Thread: Fernweh CX500 SOE's cafe build

  1. #1
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    Fernweh CX500 SOE's cafe build

    Hey all,

    I figured I should start a build thread for what I've affectionately named "The Rat" the name comes mostly from the tank. I picked this up a couple of days ago with an undiagnosed engine problem and someone has done a rat sort of job on it before the previous owner or myself got a hold of it. The name mostly comes from the fuel tank which has been sanded back to metal in some places and gone over with what appears to be lacquer which over time has developed some kind of fur.



    Here she is in all her glory:





    And lastly, here is the fur I was talking about...


    The goal is turn to turn it into a Cafe racer. The aim is the strip it down, repaint the frame, paint the engine, remove the stock bars and replace them with clip ons, put in a cafe seat and tidy the rear of the bike up. Replace the stock tacho/speedo with nicer looking units and go for a single rounded headlight and smaller blinkers. I'll be doing most of the work myself to cut costs and learning a lot along the way.

    I'm aiming to get it all done and dusted so I can ride it to my wedding on October 1st so join me and we'll see how crazy this timeline actually is.

    Contents:
    Engine Tear down, Tank paint stripping and rust painting - Page 1
    New engine from donor bike, frame strip and painting Page 2
    Rusty tank gets a make over, final drive and brakes get a paint, wheels get a paint. Cafe seat and hoop show up. - Page 3
    Tank gets painted, seat gets painted, frame gets cut up, shocks get a clean, forks get painted and some electrics underseat tidying - Page 4
    Workspace gets a clean, carbs get dissaseembled, brakes get resprayed, custom tank badges made, new engine gets dropped from old bike then cleaned followed by a paint - Page 5
    New parts arrive and get fitted, engine is mounted, garage gets an upgrade, ignition barrel relocation, electrical fun, first engine start, digital guage mounted and wired, headlight wired, electrical tidyup, carb cleaning and rebuilding - Page 6
    Battery box built, and 1st major assembly + bike porn photos - Page 7

    Cheers,
    SOE
    Last edited by Son of eevil; 01-09-2017 at 05:50 AM.

  2. #2
    JC
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    Hah, I like the name. Glad to see a build thread here on it!

  3. #3
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    This are RAT bikes :-))

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  5. #4
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    here the summary of this weekends work.
    Friday night:
    Picked up the bike and paid for it.

    Saturday:
    Unloaded on Saturday. Started her up and realised the engine problem was a little more than a few puffs of smoke and from experience it sounded like it was a big end bearing. I spent most of this day tidying up my garage to make better use of what little floor space I had so that I could fit 2 CX500 projects in there so not a lot got done until later in that evening when I set about trying to diagnose the engine fault. I puilled out the plugs moved the engine past TDC and put pressure on both pistons to feel for any movment that would confirm a big end bearing unfortunately I could feel anything at all, I checked the cam tensioner which appears to have run itself out completely and will need to be replaced/rebuilt.

    Sunday:
    I decided last Saturday night that I would need to drop the engine, if it was the cam chain causing the problem this would need to be addressed whether or not the big end bearing was gone. I dropped the oil and pulled out the filter and noticed no small amount of metal partical that had been caught, there was a mix of copper and steel in there which seems to suggest that the big end bearing has in fact gone. Oh well we'll strip her down anyway


    So I set about dropping my first twisted twin, in fact my first engine ever. Start to finish the job took me about 3 hours including a wait for the cavalry to arrive with a hydraulic jack to support the engine as we unbolted it. After pulling off the radiator I noticed that the fan was simply sitting there and hasn't bolted in at all, in addition it was pretty badly bent but on the plus side there were no stress fractures and it hadn't at any point fouled the radiator.


    So after more than a few curse words and some skinned knuckled I had the engine out planted it on my workbench and started breaking it down sending parts off to the washer as I was going.


    With the engine out and the heads off I was able to determine that the "passenger" side had indeed decided it didn't want to hang out the bearings anymore and made a short video of the sound/movement.


    That will be all for tonight. Throughout the week I'll inspect the camchain and tensioner to see what their condition is, remove the pistons, rods and Crank and speak with a local guru about some replacements.

    Stay tuned!

  6. #5
    OCR
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    I would not reuse that fan, it will be out of balance.
    Past Master, Dryden Lodge #472
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    we are all given sh*t in life, but some of us learn to turn it into fertilizer and grow from it, and some us try to fling it on others like monkeys.

  7. #6
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    Quote Originally Posted by OCR View Post
    I would not reuse that fan, it will be out of balance.
    I'm gonna heat it see if it's inclined to bend back into any sort of fan shape, I spin it up away from the engine and see what the balance is like, if it's suspect I'll just chuck it. Literally... Like a frisbee

  8. #7
    OCR
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    Simply replace it, new can be had for around $30.
    Past Master, Dryden Lodge #472
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    '79CX500C

    http://www.cx500forum.com/mediawiki



    we are all given sh*t in life, but some of us learn to turn it into fertilizer and grow from it, and some us try to fling it on others like monkeys.

  9. #8
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    Better a frisbee than a cooling fan.
    Rebuilding Handlebar Switches

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    GET A MULTIMETER RTFM I am a CX500. If you maintain me I will run forever.

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  10. #9
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    So far this week I've gotten through a lot of work.

    I dropped the engine, pulled out the pistons rods and crank. As suspected the bearings on the left cylinder were completely ruined and have taken quite a bit off of the crank as well.


    As is standard the timing chain had slapped away and eaten into the metal


    This weekend I've decided to prep and paint the tank and strip down the frame which I've decided is going to be powder coated. With that said I can't really call this the "furry" rat any more and hopefully as of Tuesday it won't even be fair to call it a rat anymore.


    The underside still needs some work but I unfortunately ran out of paint stripper


    To date on the tank, I've sand blasted all the lacquer that was on it and applied a paint stripper to the underside (Which was a pink/red colour) and have since set about sanding down any rust I've found. It has a few dents on it (6 in total) so the job for tomorrow is to pop them out as much as I can then bog them up and sand it back smooth then prime the whole thing with paint to wait until Monday.

    That's all there is for now. I'll leave you all in suspense over the colour choices but I'm pretty excited to see the end result.

  11. #10
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    Not a big update today and it doesn't look like much but I spent all day cleaning up the back half of the tank, there was SOOO much rust.... Just the hardest engrained rust it took my a drill with a wire brush a tonne of sandpaper and a die grinder to get most of it of. What you can see on the back of the tank is a rust converter + primer. This took all of my day...


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