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Old 04-05-2014, 08:08 AM   #1
layzrider OP
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Honda Hawk to a XLV 650- this is going to take a while

I wanted to improve my Transalp suspension but decided I did not want the bike in pieces for a long time. The improvements might not work either. I found a partial NT 650 cheap and bought a CR500 roller for suspension. I wanted a challenging project and I found one. I am figuring maybe a year to do this. My goal is a bike between my DRZ400 and my stripped down TA. 375 lbs, 10" ground clearance and 35" seat height. Better suspension than the TA. I really like my TA, looks and sounds good but marginal for anything but dirt roads.
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Old 04-05-2014, 08:21 AM   #2
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TA and NT

Transalp I did not want to wreck but rather ride this year.

Project Hawk on the stand.
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Old 04-05-2014, 10:22 AM   #3
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I will be doing something like that later this year, got a TA frame and a running hawk. My plan is to move the motor into the TA frame, HOWEVER if I could get a AT motor....................
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Old 04-05-2014, 11:39 AM   #4
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The Hawk is a 650

It has a few more horsepower than the 583 TA. I think your plan will be less work than mine. The TA frame is more suitable for modification.
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Old 04-05-2014, 04:01 PM   #5
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Quote:
Originally Posted by layzrider View Post
It has a few more horsepower than the 583 TA. I think your plan will be less work than mine. The TA frame is more suitable for modification.
At this point, I am trying to decide between making a rally bike or a supermotard out of it. I know of a 700cc kit for the Hawk, my concern is how reliable it would be.

Don't get me wrong, the Hawk is a great little bike to ride in the twisties, I just can't ride scrunched up on it like I used to, knees don't like it
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Old 04-05-2014, 04:02 PM   #6
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Originally Posted by layzrider View Post
Transalp I did not want to wreck but rather ride this year.

Project Hawk on the stand.
Are you going to try to use a cush drive in the rear wheel?
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Old 04-06-2014, 07:46 AM   #7
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No cush drive in the CR500 wheel

Is that a problem? The cr500 wheel is solid. Here is part of my sketch of what the bike will hopefully look like.

layzrider screwed with this post 04-06-2014 at 07:48 AM Reason: My Transalp has a cush rear wheel. Hopefully not essential
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Old 04-06-2014, 08:08 AM   #8
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Originally Posted by layzrider View Post
Is that a problem? The cr500 wheel is solid. Here is part of my sketch of what the bike will hopefully look like.
Depending on how hard you use it, snapping the throttle open, a cush drive could help prolong the live of you counter shaft. I am doing some mods on my NX650, disc brake on the rear, I am keeping the cush drive.

I am looking forward to seeing your hawk project when you finish it
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Old 04-09-2014, 03:10 PM   #9
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I owned a Hawk GT from '92 through '07 (put over 65k on it myself) . When I first got into dirt bikes then adventure bikes, I kept thinking, this Hawk could make the perfect base for a lighter-weight adventurer. Stone reliable motor, torquey without being too powerful and it's a Honda. Never did butcher mine up, sold it instead.

The limitations will be with the stock swingarm. You won't get enough travel out of that, and trying to lengthen it with a non-linkage suspension will certainly lead to challenges. Long enough forks MAY prevent a real 21" from hitting the radiator, or you may have to go dirt bike-style, one on each side. Because the bike is so small, the ergonomics may not be right once you put higher bars on it. And you'll definitely want to raise the seat a couple of inches. Please God put a decent size tank on it.....

This should be fun.
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Old 04-09-2014, 06:44 PM   #10
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Say it with me..."Rally".
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Old 04-10-2014, 08:01 AM   #11
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Not sure what you mean by Rally

You mean it won't really be a dirt bike, more of an Adventure or Rally bike. That is my goal. The rear suspension is being replaced by a CR500 system. No, it does not fit. Yet. The front is also CR500. Clearing the radiator reduces the clearance 1". The 500 radiators were just not going to work. I am also trying to keep the center of gravity low, so I am reducing the CR500 fork length 2". Trying to keep the seat height reasonable at 35". I will make a bracket to accept the 500 foot pegs, the rear sets would not work. The size of the gas tank is unknown. I will try to make it as large as possible without making it ugly. Lots of challenges on this project.
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Old 04-20-2014, 06:43 PM   #12
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I am learning frame geometry


Now I am working on the mounts for the rear suspension. I need to get creative to achieve a 35" seat height and make strong mounts for the shock tower.
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Old 04-21-2014, 05:17 AM   #13
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Old 04-21-2014, 10:11 PM   #14
Roadracer_Al
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Neat project!

I used to road race a Hawk. The fragile part of a Hawk motor is the crank, and it's HP and RPM sensitive -- a 55 hp Hawk motor will last more or less forever, but a 65 hp Hawk will only last 4 race weekends... before needing a new crank!! Do not, under any circumstances use a 10.5k redline ignition module if you have reliability concerns. When the crank fails, it fails catastrophically, destroying the cases.

Motor-wise, the guy you want to talk to is JD Hord:

http://www.hordpower.com/index.php?m...=index&cPath=1

IIRC, the 700 pistons are a bit heavier than stock, but JD can lighten them.

Tell him Al from Gang Of Nine says "hi".

Regarding wheels & cush drive, yes, you need a cush drive. Have a look at a DR650 hub, which will need to be re-laced with an 18" rim, or a KTM 950 rear wheel assembly, which is already 18".
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Old 04-22-2014, 04:29 AM   #15
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Thanks for the info

I was not planning to modify the engine anyway. Now I know I am not. Thanks for the heads up on the cushioned hub. My TA output shaft has some wear on it after 20,000 miles. Not by me. The Hawk shaft shows no wear, even though the bike was clearly run hard and not maintained properly. My old XR 350 and 250 shafts are fine. So things don't quite add up. Will it help that I ride my bikes with care? Or is the output shaft doomed without a cushioned hub.
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