I took the exhaust off the bike

I couldn't stand it anymore.

I haven't touched the bike in a little while, this is supposed to be a winter project.  I've been on the web all week looking at things I can put on the bike, bars, gauges, seats, headlamps...and so on.

I took the exhaust off the bike, it has a Frankenpipes on it.  Stock front into Kawasaki canons.  NO CROSSOVER PIPE.  Everywhere I read that taking the thing off robs you of horsepower, so out to the donor bike I go.   The stock mufflers are rotten, nothing left just a shell.  The front pipes are seized into the crossover pipe.

CX500 crossover pipe

So I started playing with the wiring.  I don't have the best memory so I tag everything.  Soon I end up with something that looks like this.

This bike was well taken care of.  I don't have to fight with any of the nuts or bolts.  After the initial crack everything comes off with fingers only.

And I guess that before zip ties they used waxed thread of some sort.  this picture isn't great but you can see the craftmanship in the ties.  I feel awfull cutting them but I don't have a choice.

Next I removed the tail section. 

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I follow the wiring to the front.  The gauge bracket comes off.  I'll be damned, all the wires go into the headlamp assembly.  Fine, I crack that open.  COOL, a sealed glass headlamp.  I havent seen one of those in long time.

Holy @#$$%^.  All I find is psychedelic spaghetti.  Check this out. 

All this is jammed through a one inch hole,  it's like a demented puzzle.  I twist, disconnect some, twist some more,  curse a little, and before I take the wire cutters to it I give up... for now. 

moved the bikes to an undisclosed location

So we moved the bikes to an undisclosed location so that we can work on it in winter.. Unfortunately we can't keep it at the shop, it's a dealership and a hacked up bike in the corner doesn't convey the image we want to portray.

With a little effort the bike made it in without me having to fix any drywall. 

I took some bits off and now I can take my time and look at what I have to work with.

We've been shredding the interweb looking for inspiration.  There is a lot of stuff out there. 

Here are some of my favorite sites:

Pipeburn
Wrenchmonkeys
Projects by Zac
Old Bike Barn
Bike Bandit
Bikeexif
the cx500forum

just to mention a few

it was a great deal we couldn't pass up

We didn't really pick this bike, it was a great deal we couldn't pass up.  That said, I am loving the possibilities that this bike offers.  Check the internet, some of these things are gorgeous.  I love the longitudinal v twin.  Not a very common engine.  I like the shaft drive.

I've never had a liquid cooled engine before so that will be new to me.  Air cooled is much simpler but the radiator piping might offer an opportunity for customization.  we'll see.

This is our first build

This is our first build.  I am using this build not only to keep myself occupied during the winter months but also to gain some skills.  I will make mistakes, that"s fine as long as I learn from them..

I'd like to try my hand at sheet metal work. I want to hand form things out of metal.  I also want to give welding a go.  That's right, I don't know how to weld. 

I have the paint part down pretty well.  I've painted my bike a different colour every year.

Paint is a simple enough thing to do and now that I have that under my belt it's time to go bigger.

I've also dabbled in custom leather for my present ride's seat.  Here is what came of that.

We'll start with the usual.

Cut the frame.
Change the handle bars
Maybe change the instrument cluster.
Do something with the exhaust, not sure what yet.
Make a seat.
Try making a little fairing.
Get rid of the air box.

And of course getting it mechanically sound.

I have two very good friends helping me out and a garage full of experience and advice to lean on.

Here is what we are dealing with in the tank

Here is what we are dealing with in the tank.

Got the tank at home and dumped a bottle of Evapo-rust in it.  We'll see how much of the crap it will get out.  I'm looking into products lo line the thing.  Lots of them out there.

I'm starting to get some of the tools I might need.  Picked up an angle grinder, dent puller, a small anvil and some body tools.  I'd like to try my hand at making something out of sheet metal.

We picked the lock on the custom gas tank, and Mr. Double J recoded it for the key that we have.

I'm already thinking of colour schemes but that"s a little premature.  I've cot a copper fetish but we'll have to see.

This will give you a idea what we are starting with

This will give you a idea what we are starting with.

Still debating which tank to use.  I like the Custom's gas cap doohickey and it's clean inside.  I like the Deluxe's shape. but it's all rusty inside.  We'll see.

We got the bike back at the shop and started tinkering

One more week done.  We got the bike back at the shop and started tinkering.

Now keep in mind that Mr. Double J is working on this for about an hour and a half each day, half an hour befor work, half an hour after work ansd maybe during lunch.

We where a little worried because the rear wheel wouldn't turn with the bike  in gear. Mr. Double J thought that with a little oil down the cylinder head we might break it free. 

No sooner had he poured oil in them it started leaking out of the bottom of the head.  WTF!!  A hole in the side of the heads was letting oil out.  See the picture.

You have to remember we are car guys, we don't have holes in heads.  We are wondering what fittings are missing or what thingy was supposed to go there.  After about an hour of going about our daily grind Mr. G figured it out.  They where drain holes for the spark plug tubes. Big sigh. 

Here is the bike in the shop.

Let it sit. 

Hook it up to a spare battery and charge it up.  Give it a go.  Good news, it turns over.  Its no longer seized.  This is where Mr. Double J gets a little cocky.  " I should have it running by the end of the week".  Hold up, you kidding me?  We have no idea what kind of shape the carbs or the engine are.

We get spark about midweek.  Carbs are in the parts department getting cleaned. 

Thursday instead of lunch Mr. Double J gets the darn thing going.  Mr. G and I rush outside and are greeted with a triumphant yell from Mr. Double J who is slightly clouded by a cloud of smoke. 

This is what we have.

She sounds sweet.  It won't run off choke but it runs.

I have to give it to him, Mr Double J is a talented man.