Honda FT500 rumbler/scrambler/tracker kinda thing

Discussion in 'Some Assembly Required' started by fotoduda.com, Jul 20, 2012.

  1. fotoduda.com

    fotoduda.com Adventurer

    Joined:
    Jul 19, 2012
    Oddometer:
    82
    Location:
    Lechistan
    I went for a ride thru the woods on (Any) Sunday and lost the side stand. The new shocks are a bit too stiff.

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    Luckily last week I took a delivery on this :D

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    Today after about 6 hours of work I managed to create this:

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    First attempt went pretty badly, when I tried to tilt the bike on the stand it snapped right off. I realized my welds didn't penetrate shit. I readjusted the machine and made new welds. When they looked bad I grind them down and did them again till they looked solid. So far it holds on just fine.
    #61
  2. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
    Sep 8, 2011
    Oddometer:
    142
    Location:
    On the Roads of Motherland
    Nice first-time welding !
    I have a spare original sidestand that I'm planing to abuse and extend in length and increase slipper surface.
    #62
  3. jurvooss

    jurvooss Adventurer

    Joined:
    Sep 30, 2011
    Oddometer:
    17
    Oi man,

    He i have a question about your genius way of making the speaker jack into the kill switch and the other switches. but u said you found it on the corpses from hell blog, but where i couldnt find it! can u also please give a little more feedback about the killswitch and other switches on the alu. side panel, how did u do it? did u used standard switches? do u just used the standard wires and soldered them onto the switches?

    please let me know,
    greets Jurgen
    nice bike man, love the tank!
    :freaky:ear
    #63
  4. fotoduda.com

    fotoduda.com Adventurer

    Joined:
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    Location:
    Lechistan
    I've seen that jack switch on Corpses From Hell on one picture and there were no instructions.

    First of all I got rid of all unnecessary from the original wiring. No clutch kill switch, no neutral gear indicator, no turn signals. Than I studied carefully the manual's wiring diagram and removed the ignition switch. It does basically two things: provides power for lights, starter, horn etc. AND grounds the ignition. So I made my loom in a way that all the components that need power get it thru the jack plug. Ignition coils on the other hand do not work when they're grounded, and work when ungrounded. That's the switch next to the jack plug. Than added a pull switch from my brother's VW beetle for lights, and another switch for low/high beam. Couldn't figure out how to do it in one switch cause of the rear light. It's all mounted to a plastic plate, and soldered behind it. I learned that it's better to use stereo jack plug, cause than you can mount it on a metal plate. I also have a horn and starter buttons on the handlebars.
    #64
  5. fotoduda.com

    fotoduda.com Adventurer

    Joined:
    Jul 19, 2012
    Oddometer:
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    Location:
    Lechistan
    Last month I had big fuck up. Doing 100km/h I suddenly lost power, stopped on the side of the road and the engine died on me. Turned out there was no oil in the motor. I topped it out some 800km earlier and didn't notice it was all gone until it was too late. After replenishing the fluids (of the bike and myself) it started again and I rode home in a cloud of smoke.

    After opening the engine it became apparent, that I had sustained mild seizure and the piston was a goner.

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    I ordered a new Wiseco piston and gave it to the machine shop for the cylinder honing. When it was ready and it was time to put it back in I noticed that the piston pin is the wrong diameter for my crank arm. At that moment I reexamined the piston just to find out that the serial number on it didn't match the one on the box. Also it had a different compression ratio and only 2 holes for the valves.

    So it took another week to return it to the shop. Of course the supplier didn't have the right one and I ordered a Wossner one instead. In the mean time when I had the whole bike disassembled I got to work. I got the wheels powder coated black and replaced all the bearings. Also the new rear suspension was way to hard for my liking and I took it apart and put on it the old springs, little hacking was involved to get it all done, but now it works perfect.

    I checked the valve seals while in there, it was a good idea, cause they were just hardened plastic after 30 years of abuse. The only way to remove them was to brake them apart. The cam chain was also out of spec and had to go.

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    The tank got a new paint job:

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    Little touches:

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    Last, but not least, I got a TKC80 on the front and a plastic bag for the seat :D

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    #65
  6. VittoXVIII

    VittoXVIII Adventurer

    Joined:
    Mar 1, 2013
    Oddometer:
    17
    Location:
    Italy, Genoa
    I'm so loving this!
    A true hardcore bike, keep it up!

    :freaky:freaky
    #66
  7. ValuePack

    ValuePack Adventurer

    Joined:
    May 23, 2012
    Oddometer:
    26
    Location:
    Manchester, NH
    This bike just gets cooler with every update, looking forward to more!
    #67
  8. Rango

    Rango Phaneropter

    Joined:
    Oct 30, 2012
    Oddometer:
    1,203
    Location:
    Kingdom of Belgium
    Great write up. Loving it. Subscribed
    :1drink
    #68
  9. fotoduda.com

    fotoduda.com Adventurer

    Joined:
    Jul 19, 2012
    Oddometer:
    82
    Location:
    Lechistan
    Rember when I said the suspension is perfect now? Turns out I was lying to you and to myself. Last Sunday I took a nice 100km ride mostly thru the woods, and the bike got a little beat up. It was so shaky that something broke loose in the silencer and now is rattling all the time. I had to get of my arse even for the small bumps, and I don't like to get off my arse to often. Who likes? So today I went mental with the MIG and created new suspension mounts. I put them about 10cm lower to the original ones, the shock lays more horizontal by about 20 degrees. Turned out really well. I gained some suspension travel, from petty 84mm to mighty 100mm :clap

    Here are some shitty pics. As always I forgot to bring my camera. And even if I did, I was is in such a working frenzy that I would forget to take pictures anways.

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    Now it rides like from Coupe De Ville, took it to my test trail along the train tracks, goes really smooth and soaks up all the small and mid size bumps.
    And I can always set the spring preload harder if I need.

    Geat Succezzzzz! :lol3
    #69
  10. lord_oblivion

    lord_oblivion Been here awhile

    Joined:
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    Oddometer:
    142
    Location:
    On the Roads of Motherland
    Nice improvement, for off-road !
    Did you try it on-road, hi speed cornering? Wobbling while leaning..?
    #70
  11. fotoduda.com

    fotoduda.com Adventurer

    Joined:
    Jul 19, 2012
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    Location:
    Lechistan
    I'm only 300km into the new piston brake-in, so no high speed cornering for me now ;)

    I usually go 120km/h tops, once pushed it to like 150 and that was it. The engine was already begging for mercy and I had to cling to the bars like crazy. I see no fun in going that fast without a windscreen. I don't mind a little sacrifice in that area for the off road capabilities.
    #71
  12. fotoduda.com

    fotoduda.com Adventurer

    Joined:
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    Oddometer:
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    Location:
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    Believe it or not, last Saturday I lost the air filter on my bike. It fell out somewhere on the rough dirt road, 40km from home, I never saw it again. Almost bought a new stock one, but I've found a bargain on a K&N. Say no more. I was waiting for a long time to throw this big air box out of the way. The only problem was that my carburetor had a 54mm diameter, and this filter was 57. But, as someone told me before, one problem is no problem. I cut a rubber band out of a bicycle inner tube, put it on the carb and the filter fit right in.

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    that's my crankcase breather filter if you ask...

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    my mate Lukas gave me his bent BMX handlebars, I put them into use right away

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    the frame is ready, finally I can get on with the seat pan and upholstery

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    The battery is at the same place it use to be. I utilized the lower part of the original basket, had to weld back a broken tab, and used a very stylish leather strap to hold it tight. It really ties the room together, don't you think?
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    #72
  13. Rango

    Rango Phaneropter

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    Most creative!

    The pictures are beautiful, some go way beyond the ordinary image; especially the last one sits comfortably in the artsy corner: great atmosphere. :clap
    #73
  14. Chico

    Chico Thief and Saboteur

    Joined:
    Oct 24, 2005
    Oddometer:
    754
    Location:
    Brooklyn
    I like your style, Dude.

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    #74
  15. dpforth

    dpforth no inline fours

    Joined:
    Oct 22, 2010
    Oddometer:
    348
    Location:
    Fantasy, I mean Vancouver Island
    Or, Duderino, if you're not into the whole brevity thing. :D

    Love watching the evolution of this bike, you're having fun with it!
    #75
  16. fotoduda.com

    fotoduda.com Adventurer

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    Lechistan
    Does the Pope shit in the woods?:wink:
    #76
  17. Kernel

    Kernel Been here awhile

    Joined:
    Aug 6, 2010
    Oddometer:
    170
    I don't know mate but I bet he shits in a pretty bloody nice toilet.
    #77
  18. Rango

    Rango Phaneropter

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    Either way it's holy shit. :evil

    Sorry OP, give us another picture to deliver us from our silliness. :fpalm
    #78
  19. throttlemack

    throttlemack n00b

    Joined:
    Jul 23, 2013
    Oddometer:
    1
    Fotoduda,

    Kudos to you. Awesome writing and great bike!. can wait to read more :lurk

    Question,
    Do you are anyone, knows where I can get a manual for the FT500?
    I bought my second bike last saturday and I'm taking it apart already for some customisation.
    Any help would be appreciated.

    Cheerio
    #79
  20. fotoduda.com

    fotoduda.com Adventurer

    Joined:
    Jul 19, 2012
    Oddometer:
    82
    Location:
    Lechistan
    PM me, I have one in PDF to spare :evil
    #80