« Posts by faber

Seal and Coil replacement complete!


Finally received the rest of the parts I needed (exhaust gaskets) to complete the rebuild, everything looks great, ran it around the block and it’s running like a champ. I did notice that the right side rockers are making a bit of noise, so I’ll adjust those again, soonish, that said, the bike sounds great and is running wonderfully.

CX500 stator and seal replacement part 2

With all the seals in hand, and a few hours of work today I was able to actually finish most of the engine work on the CX500.

IMG_20140419_105336The new stator is in place and the CDI advance pulser has been removed. I was also able to significantly reduce the number of wires coming out of the back of this engine. So now I have 1 ground, 2 pairs of high speed coil wires. 3 power wires off the stator coil and the neutral indicator switch!

IMG_20140419_105324New oil seal is installed… This was a bit of a pain. the various ’79 microfiche indicate a totally different seal size, so I had to track down the right seal for the job (what a pain!)

IMG_20140419_105415After closer inspection, the shift cam tensioner spring was a bit tired, so when I ordered the new water pump oil seal I also ordered a new spring

IMG_20140419_105443Since I was trying to reduce the amount of oil leaking out of this thing (which wasn’t much) I took the opportunity to replace the shift shaft oil seal. This is primarily where most of the oil drips would come from, that said, it wasn’t much at all and I would only find a few drips after a long ride and allowing the bike to sit in place for a few days.

IMG_20140419_105933IMG_20140419_105941Also, when I scraped off the old rear engine cover gasket I noticed that coolant had penetrated it. This was due to the o-rings which you see above (new ones installed in these pictures). So those got replaced as well.

IMG_20140419_111153New gasket is installed. Time to button her up.

IMG_20140419_114731One thing I should have noted here (which I didn’t get a picture of before reassembly) is that if you have a failed mechanical seal on the water pump, NOW is the time to replace it. It can be replaced while the engine is on the bike and rear cover is on, however it’s not a simple job.

With the rear of the engine back together it’s time to address the oil leak out of the clutch arm on the front of the engine.

IMG_20140419_121324This little seal, no bigger than a dime has been a massive annoyance to me. It weeped oil out right at the clutch arm shaft and would end up coating everything behind it (due to wind blowing it everywhere)

IMG_20140419_121318The seal took all of about 2 minutes to replace, and another half an hour scraping the old gasket off.IMG_20140419_172607You can clearly see where it was leaking…. How annoying.

Any who, with some effort I was able to reinstall the engine on the bike by my self.

IMG_20140419_172624Next step is to torque everything down, reinstall the radiator. oil and coolant, etc. Likely this won’t happen this weekend as I’ve decided to replace the exhaust gaskets as well. They look alright but probably will leak a bit, so I’ve got another set ordered and they should be here shortly.



Yesterday I padded my wallet a bit and sold the SV1000S. This bike was great, After it was all said and done, my work put into it, and the extra parts I sold off before selling it, I made a tidy profit after putting 4K miles on it.

The new owner loves the bike and it appears to be going to a great home.

CX500 stator and seal replacement

The CX500, minus just about everything!

CX500 /wo engineAs you can see, the engine is removed! Over the summer I noticed the stator got worse and worse until I nearly ended up stranded with a dead battery. So the first step is to remove the tank, side panels, foot break, carburetors, electrical etc. etc.

CX500 radiator /w sensor and electric fan modI was pretty pleased to see that the electric fan modification I did on the radiator is holding up well. The paint is holding up pretty good as well, although some has been scratched off around where the radiator inlet pipe is.

CX500 M.A.C. 2-IN-1 titanium wrapped exhaust and headers The other thing was pretty happy about was the condition of the M.A.C. exhaust system and how well the titanium wrap job is holding up.

CX500 engine with rear cover off

Got the engine up on the bench this morning and popped the rear cover off. Man theres a lot of bolts on this thing. While removing the cover was mindful not the disturb any of the seals for the final shaft, shifter, or oil and mechanical seal on the water pump shaft. That said, I’ll need to order a new shifter seal, as well as new copper washer for the water pump (If I can’t find one) and possibly two new o-rings for the cylinder jacket what pass through pipes

CX500 starterAs you can see, the starter gear is in great shape. This reduction gear on the engine is also in nearly new condition, which is really nice to see on a bike this old!

CX500 engine starter reduction gearBoth gears on the starter reduction gear on in nearly perfect condition.

CX500 engine lower rear CX500 engine gear selector starThe gear selector and selector star are both in great shape. This is an interesting design for a selector star, usually you don’t see them with pins to provide the indexing. That said, I guess such a system would probably last a whole lot longer.

The other thing I noticed (which is hard to see). Return spring on the selector shaft came (the shaft which protrudes through the rear of the engine) appears warn, so I’ll order a new one of those, hopefully it tightens up the gear selector a bit.


Timing chain tensioner CX500 Timing chain CX500Checking on the timing chain things look good. You can see, given the position of the cam chain tensioner that the chain will need to be replaced in the next 10K miles, so another job for another time. There is still some room on the tensioner (though not much) and there is zero slop on the chain.

CX500 engine final shaftThe final shaft, with damper assembly is in great shape. The lobes on the damper cam show very light ware, the shift is nice and tight and I expect many more years out of this.

CX500 engine G47 state /w pulsers CX500 engine G47stator /w pulsers (2)The offending unit. Here’s the old G47 stator and pulser assembly. The first thing that failed on this stator was the source coil (which you can see by it self on the stator assembly). These G47 style stators are extremely complicated with a bit of a mess of wiring.

The new stator will be a G8 style unit from a newer bike. Normally you can’t run these in the old CX500’s with CDI control systems, however I’ve replaced the control system with a much better Ignitech black box.


CX500 engine rear cover water pump, oil and mechanical sealYou can see that the oil seal has seen better days so I’ll replace that while I’ve got the rear engine cover open.

CX500 G47 stator (removed)After some quick work with the air tools and some wire cutters,  I was able to extract the old G47 stator core from the rear cover.

CX500 G47 stator and pulser wiring harness

Next task is to figure out how much of this wiring bundle I can do away with. I suspect given that the Ignitech only needs pulser data, I will be able to get rid of quit a few of these wires.  This will be nice as it reduces the overall clutter, it also takes the weigh down a few onces 😉

XS400 Sold!



Well it’s sold! Made a few bucks on it, covered the parts I put into it and moving on.

Based on my experience finding XS parts, and the build quality in general I think I’ll stick with Honda’s in the future.

That said, the next owner is happy with the bike and will enjoy it until he’s ready for something a little more powerful.

1979 CX500C, time to sell it!

Well the CX500C is finally completed. It’s time to put it up on the block for sale. Here’s some parting shots of it before I let it go to the next owner


So form the last set of pictures a few changes, header wrap, cleaned =)

Paint day for the CX500 side panels and XS400 body parts

Finally got the CX500 side covers painted, I’m really excited as this is the last major bit of the puzzle on this bike

We also managed to get the XS400 tank, starter cover, and side covers painted. They’re a really neat burnt copper finish and should look great on this ratty old bike

Quick update on the XS400

Today after work I put a spare fuel bottle on the bikes and filled the carbs for the first time since they were rebuilt. Plugged it all back in and fired it up.

After a quick vacuum balance with my DIY manometer the thing was running pretty good. I still have a bit of a idle down lag at 3K rpm’s but it’s a whole lot better than when I got the bike (or before I vacuum balanced the carbs).

I’m still working on getting the tank and fenders completed, but as it stands now, with the temporary fuel bottle hooked up, I can actually ride the thing around and get an idea as to it’s overall performance.


XS400 and CB900 tanks stripped and ready for more cleaning

Well I managed to get the XS400 and CB900 tanks stripped down. On the XS400 tank there is a bit more work to remove some of the more stubborn paint around the lip but that shouldn’t be too bad. This weekend I’m hoping the new charger arrives so I can strip the inside of the tanks next.


BS34 carb pack back together for the XS400

Today I finished reassembling the BS34 carburetor pack for the XS400 project, it came out pretty well.

Upon disassemble I noticed that the right side carburetor main jet was completely turned out and sitting loose in the threads at the bottom of the bowl.

On the left side the float valve housing was loose because it’s O-Ring had failed.

Both carburetors got a total top to bottom internal cleaning with the ultrasonic.