CX650 "Custom" ADV bike build

Discussion in 'Some Assembly Required' started by SloMo228, Oct 11, 2012.

  1. luckychucky

    luckychucky Long timer

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    #21
  2. DRjoe

    DRjoe Long timer

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    Have you considered making spoke wheels.
    Maybe you could cut the rim and spokes off the original rear wheel and then machine it down and put spoke holes in the hub so that you can fit any rim you like.
    You would need to make friends with some one with a mill and skills to use it.
    #22
  3. SloMo228

    SloMo228 World Class Cheapass

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    Well, despite today's setback, I got some more work done. I got the triple clamps cleaned up and painted, then installed them with the new XL forks. I'll have to take it all apart again to replace the fork seals, but I needed a little inspiration seeing the thing look like a motorcycle again:

    [​IMG]

    I mocked up some mini gauges I had in my parts pile from an old project, I don't mind the look of these:

    [​IMG]

    I'd prefer one of the all-in-one digital gauges like the Acewell gauge or the Danmoto SP2, but that's not in the budget for this bike (especially since I might have to search out a CX650 Turbo rear wheel). Maybe someday down the road, but these will work for the time being, and I kind of like the offset mounting. I'll just have to make a little dash panel for the idiot lights and temp gauge, maybe add a USB port for charging a GPS/phone.
    #23
  4. ktmklx

    ktmklx Been here awhile

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    This looks like a neat project. Do you know how much rear wheel travel you can get with the 650 shaft set up?
    #24
  5. SloMo228

    SloMo228 World Class Cheapass

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    The swingarm actually has 14" of travel from stop to stop, but I want to limit it some to avoid damaging the shaft. I'm thinking I can probably get around 8" of usable travel, and I'll try to set the sag so that the suspension is fairly level when I'm sitting on it so most of the operation will be in the normal range of the driveshaft - I'm no dirt racer, so if I do ever get to the limits of my suspension travel, it will only be briefly, so any extra wear from increased driveline angle should be minimized.
    #25
  6. SloMo228

    SloMo228 World Class Cheapass

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    Had a bit of free time today so I headed back out to the garage. I got a couple new parts, namely handlebars and seat, so I mounted the bars and mocked up the seat. Then, I was looking through parts from old projects and found a fender that I'd once used on my GL1000 as a swingarm-mounted "hugger" type fender. I cut the support struts off of it and set it on the back of the frame just for laughs. It was a pretty damn close fit, just the rear end of the frame was interfering. So, I lopped it off:

    [​IMG]

    I welded up a mount for the front of the fender, bent the edges out a bit at the front for clearance, and it looks pretty good on there, I think. I mocked everything up for a couple shots:

    [​IMG]

    [​IMG]

    I probably won't get too much farther on it for a week or so, my schedule is pretty full. But so far I'm pretty pleased with how this project is coming along. The only real sticking point is the wheels, but I still have a couple of ideas to try out on that front.
    #26
  7. SloMo228

    SloMo228 World Class Cheapass

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    No luck on the CX500 Comstar wheel. The drive flanges are the same bolt pattern but the hub itself is different and won't work with the 650 final drive. :dog

    So, it looks like my options are either to go with a CX650 Turbo 18" rear or get a custom rim for a VT800 spoked rear hub and offset it appropriately for the 650. Neither one would be a particularly cheap option, unfortunately. Still, even if I do either of those, my total cost for this bike is going to be less than $1500. I was hoping to keep it under $1K but I don't think that's going to happen.

    I'm going to leave the rear wheel issue on the back burner for now and finish up the rest of the bike first.
    #27
  8. SloMo228

    SloMo228 World Class Cheapass

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    I had an hour to kill today in between errands, so I headed to the garage again. I built mounts for the seat:

    Front mounts:
    [​IMG]

    Rear mounts:
    [​IMG]

    And with the seat on:
    [​IMG]

    [​IMG]

    I don't like how the fender just cuts off where it does, but I'll probably just leave it for now since I want to ride the damn thing sometime soon. Tomorrow I'll get the gas tank mounted, then really the only things left are rebuilding the forks, rebuilding the carbs, painting, and getting new wheels/tires. Oh, and trying to stuff all the wiring into the new headlight shell. :lol3
    #28
  9. SloMo228

    SloMo228 World Class Cheapass

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    Today, I mounted some dirtbike-style pegs:

    [​IMG]

    They needed a little bit of grinding and welding to fit and sit level, but nothing major. I wasn't able to get the spring to fit in there, so I went without. Don't really need it as far as I can see. :dunno:

    I also started on the exhaust:

    [​IMG]

    I wish I had a tube bender, it would make this part of the project much easier. But it won't be too bad anyway, I'll just have to buy pre-bent tubes and cut/fit.

    I also worked on getting the gas tank mounted, but didn't actually progress any on that front. I'm still puzzling it out in my head, trying to figure out the best way to mount it.
    #29
  10. SloMo228

    SloMo228 World Class Cheapass

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    I've been really busy lately with work, and exams are coming up in class, so I haven't had a lot of time to work on the 650. But I did get about an hour yesterday afternoon to get out to the garage. I made up some front gas tank mounts:

    [​IMG]

    I also got my spoked rear wheel and mounted it:

    [​IMG]

    It needs new bearings since the VT800 it came off of had a 20mm rear axle and the CX650 has a 17mm rear axle. But that will just be a matter of finding the right size bearings. I haven't double-checked but I think the CX650 bearings will work in the VT800 wheel. Once I have it mounted properly, I'll be sending it off to Buchanan to have the hub laced to an 18" rim. I have a 21" spoked wheel for the front on its way.

    Here's where she sits now:

    [​IMG]

    It's in the frustrating middle stages of the project, where most of the dramatic big changes have been made but there are still a lot of little things to do that always end up taking twice as long as you expect. But I'm still pleased with how it's coming along.
    #30
  11. SloMo228

    SloMo228 World Class Cheapass

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    The CX650 drum brake didn't work with the VT800 wheel, so I ordered a VT800 brake. It fits perfectly:

    [​IMG]

    Gotta love Honda parts-bin engineering.

    I have proper wheel bearings on the way to match the VT800 wheel with the CX650 rear axle, so the only remaining issue with the rear wheel is that the drum brake plate has a 20mm hole. I need it to be 17mm. But looking at parts fiches, it looks like there is a bushing pressed into that hole that rides on the axle. The 650 brake plate is the same. I should be able to press out the bushings and swap them. Then I'll be ready to send the wheel off to Buchanan to have them lace a new rim to it.

    Would it be better to have a 17" rear or an 18" rear? I'm not really sure. Most of the tires I'm looking at are available in either diameter.
    #31
  12. gkam

    gkam Adventurer

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    You have more choises for off road tires on the 18" rim.
    Most on - off (dual sport) tires are 17".
    #32
  13. oregoncoast

    oregoncoast Racing Like a Noob

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    :lurk
    #33
  14. SloMo228

    SloMo228 World Class Cheapass

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    I really wish I had more time to devote to this build, but I am always super busy at the end of the year (isn't everyone?) so I have only been able to work on the bike for an hour or so here and there. I want to ride this damn thing! :D

    Anyway, I got out of work early today so I headed home and went out to the garage. I got my front wheel in the mail, so I mounted it up:

    [​IMG]

    Looks nice on there. I have to make some spacers for it, it's sitting about an inch too far to the left right now. But nothing major. So then I was standing there staring at the thing and I decided it would look much nicer with an empty rear triangle. There's actually quite a bit of room between the tank and the frame, so I think I can hide most of the electronics up under there. I pulled out the airbox and battery box, and unwrapped the wiring harness looking to see where I could shorten it up. Turns out there's a nice long run of wires, about 16" or so, without any splices or connectors or anything, that I could just cut out of the harness to make it shorter. So, I took a deep breath, grabbed my wire cutters, and turned this:

    [​IMG]

    Into this:

    [​IMG]

    It was at this point that I discovered that I am out of solder. :lol3 Oh, well. I'll get some time to work on it later this week. The scope of this build has gotten quite a bit bigger than I originally anticipated (doesn't it always?), but I like where it's headed.
    #34
  15. wingnut11

    wingnut11 generally strange

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    Just want to say, keep up the good work. As a former cx500 owner I often have daydreams of getting another one and doing this kind of thing to it. Can't wait to see it finished.
    #35
  16. SloMo228

    SloMo228 World Class Cheapass

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    Well, it's been a while, and this post certainly sticks out in my memory. :lol3 Like most projects, things haven't gone quite to plan. Work, school, and purchasing a new house have really put this project on the back burner for me, but I'm hoping I can button it up before I have to leave my current place. I don't think I'm going to go "all the way" with this project anymore since I snagged a DR350 for $600 that will make a much better commuter and off-roader, but I hate leaving projects unfinished, so I'm at least going to get this back on the road, then probably sell it.

    Unless someone is looking for a low-mile CX650 engine for a swap, that is.
    #36
  17. SimpleSimon

    SimpleSimon Aspiring advrider

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    Bummer. I thin you have a very cool project on your hands. You have done the bulk of the hard work alread! :norton
    #37
  18. SloMo228

    SloMo228 World Class Cheapass

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    Well, if I can manage to sneak it into the new house without my better half noticing, maybe I can finish it up this summer. Right now she's convinced that 5 motorcycles are too many, for some strange reason... :1drink
    #38
  19. jon_l

    jon_l Long timer

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    Hey Slo - what's up with your CX project?
    #39
  20. Beezer

    Beezer Long timer

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    ya, looks like most of the hard stuff is done. should be pretty kool when completed. I did a project with the GL version of that bike.... possibly the most orphaned thing I've ever worked on. I have some sources...
    #40