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Thread: CX500 - My Restoration in progress

  1. #21
    Member elrodicater's Avatar
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    3/4/17 UPDATE

    Doing a complete restoration takes a lot of patience and planning. Today I carefully packed ALL of my painted fairing/fender/side cover pcs and sorted my decal kit so my painter only gets what I want installed. I included the 2 tone paint masks I purchased to spray the gray second color. I packed them individually and with packing foam so that when they get completed, the painter knows what box they go in and they are ready for the return home. I figure they wont take the time so if I do it for them, the result will be what I expect.

    I then got my second shipment ready for the powder coater. That is basically all of the exhaust and the turbo shields and manifolds. That means I had to drill out the exhaust tips and carefully drive them out of the mufflers. The tips go to the chrome plater now..
    I spent considerable time heating the exhaust shield retainers and backing those JIS screws out. I did have one break, but was able to slot it with a die grinder and turn it out with a screwdriver after getting the metal glowing hot. Good times.

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    nolimitz likes this.
    ...Restoring my 12k CX500 turbo after 21 years of storage....

  2. #22
    Member elrodicater's Avatar
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    3/5/17 UPDATE

    Today I rebuilt the rear master cylinder. The challenges you run into are not always what you anticipated. I used a KL kit which is commonly listed. I had 3 issues with this kit.

    1) It omits the O ring for the reservoir adapter.
    2) The seal on the piston does not come pre installed.
    3) The accordion boot finish is a white chalky faded finish. My 35 yr old original looked better.


    This may not sound like a big deal, but just try installing the piston seal on the piston. The seal has be stretched 400% over the piston land - impossible without damaging it. After 2 tries, I built a seal install tool using the tip of a caulking tube. By carefully sizing it to snap over the piston, I was able to slide the seal down the install tool and get it up and over the piston land. I consider this very weak from these kits. But since it's the only game in town - we find ways to make it work.

    The housing was then cleaned up, primed/painted/sealed. I used Forever Black to put some permanent color on the new boot seal. I polished up the passenger foot rest plate and bolted it all together. After scrutinizing the reservoir hose internally, I decided that will be replaced with an aftermarket bulk hose. Way to many crystals and garbage inside to keep.
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    glrider and CXPHREAK like this.
    ...Restoring my 12k CX500 turbo after 21 years of storage....

  3. #23
    Senior Member edinlr's Avatar
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    Pretty sure you just want to polish that muffler end cap, I don't think any of them came with chrome. Bad news about the K&L kits, I have a stash of those for my bikes, disappointed to hear the quality is so bad.
    CX500C
    CX500T
    CX650E
    CX650T
    Hawk
    CB750 w/turbo
    RG500
    V-Max
    Kawasaki 750 Turbo
    Katana 1000
    Ducati 749R
    Screaming Eagle Road King
    CBR600F3
    Honda Metropolitan
    Ninja H2 1000
    & a dozen battery chargers

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  5. #24
    OCR
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    Warming the seal up before install would help too.
    Past Master, Dryden Lodge #472
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    '79CX500C

    http://cx500forum.com/mediawiki/inde...itle=Main_Page



    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.

  6. #25
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    for all the seals for the heat shields, I made them out of heat resistant gasket sheet painted a light frosting of silver engine paint. See here.

    79 CB750F Super Sport
    76 GL1000
    82 CX500TC

  7. #26
    Member elrodicater's Avatar
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    I was curious that you may have made your own Nunzio! I saved what was left of mine to create templates. That engine of your looks amazing!
    ...Restoring my 12k CX500 turbo after 21 years of storage....

  8. #27
    Member elrodicater's Avatar
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    Quote Originally Posted by OCR View Post
    Warming the seal up before install would help too.
    Great idea! maybe hot water vs air so the seal wouldn't dry out? I thought I was Mr Clever using the tip of an old caulk gun.. LOL!
    Last edited by CXPHREAK; 03-06-2017 at 06:52 PM.
    ...Restoring my 12k CX500 turbo after 21 years of storage....

  9. #28
    Super Moderator CXPHREAK's Avatar
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    Quote Originally Posted by elrodicater View Post
    Great idea! maybe hot water vs air so the seal wouldn't dry out? I thought I was Mr Clever using the tip of an old caulk gun.. LOL!

    I reckon it's a clever idea.

    I also reckon I'll pinch it.
    Rebuilding Handlebar Switches

    http://s1085.photobucket.com/user/CXPHREAK/library/Switchgear%20rebuild?sort=6&page=1

    Rider 81 500C, Thingy Born a 78Z. Ozdeluxe born an 80 shadow.

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

    http://cx500forum.com/mediawiki/inde...itle=Main_Page

  10. #29
    OCR
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    Yep, put the seal into boiled water for a minute before installation.
    This will allow it to stretch easily and slide on without tearing.
    A little oil on your tapered adaptor will also help.
    Past Master, Dryden Lodge #472
    Caroline Lodge # 681
    RAM Fidelity # 77





    '79CX500C

    http://cx500forum.com/mediawiki/inde...itle=Main_Page



    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.

  11. #30
    Super Moderator CXPHREAK's Avatar
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    A little brake system compatible rubber grease would be even better.
    Rebuilding Handlebar Switches

    http://s1085.photobucket.com/user/CXPHREAK/library/Switchgear%20rebuild?sort=6&page=1

    Rider 81 500C, Thingy Born a 78Z. Ozdeluxe born an 80 shadow.

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

    http://cx500forum.com/mediawiki/inde...itle=Main_Page

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