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Project New Bike - Plastic Maggot - CX500

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Andych, Sep 5, 2024.

  1. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    OK, so I have decided that the Triumph, as lovely as it is just doesnt get ridden enough (500km since I bought it new) so I will be selling that in the very near future and it just so happens my neigbour 2 doors up mentioned he had his fathers bike up for sale (his dad passed away about 9 months ago).
    It is a 1983 CX500 Shadow (base model) otherwise known as the Plastic Maggot, that for its age is in pretty amazing condition.
    It isnt quite as good in real life compared to the pictures but nothing some chrome polish etc wont fix.
    There are no oil leaks and it cranks and starts easy, idles lovely on both cylinders and feel really strong.
    Its not a race bike but does have a lovely note to it (as most Honda twins do).
    43,000 km on the clock (original mileage) in 43 years...
    I think the only thing I will probably do is look at changing the tyres.. The rear is a Shinco and not sure about the front.
    It has been on Club Rego (Still has the plate) so it will be going back on Club Rego... there will be plenty to do on it even just tidying it up as well as sorting out the Thermo fan conversion and making sure the cam chain is right... anything else I will find along the way.
    Oh, I forgot,, the front cowling needs to be painted and when I get the bike (on the weekend) I will confirm the pain number and look to getting that done soon.

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  2. 2valve

    2valve Well-Known Member

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    Hi Andy
    Bike look's very nice for it's age :thumb_ups: , and being two door's up , no huge transport cost's involved.
    Cheap rego to , another great bonus.
    Had one back in the day's , i loved it , so comfortable on long trip's and still had power on tap , even being two up.
    Mine was pretty quick too if needed.
    Mine was only a front single disc though , so i thought my model would have been the base model , can't remember what year model mine was , i have a few picture's of it back in the day's.
    I traded it on a new Honda VF750FE , worst bike i've ever owned.
    Your radiator shroud look's to be metal , mine was plastic.
    Right , so we'll start with a upside down front end first , easy job , this will only take a day , and then we'll move onto the rear shockie's :lolsign:.
    Then bolting a Turbo on , this will give you some serious extra HP you'll never use , but , it'll sound sweeeeeet when heading to pick up your cappuccino.
    Have i missed anything ;).
    Doe's that mean i'll finally be receiving that old Yamaha sitting in the shed ;).
     
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  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    The beauty of this bike is its originality so no USD forks or Turbo etc
    Mods will be for reliability only and hopefully hidden


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  4. Frankster

    Frankster Grey Pride...Adventure before Dementia Premium Member

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    Yours must have been the original 1978 launch model.

    Great pickup @Andych; I nearly bought one a few years back from a mate of Mr. @Murdo
    I've always liked these bikes and even the Turbo 500 and 650 have reasonable reliability. There's an entire forum for this bike so you'll have plenty of help (if needed). https://www.cx500forum.com/
     
  5. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Cheers @Frankster
    I am already scouring for the best E-fan conversion and it seems to be using a Kawasaki ZX6R fan... they seem to be hard to find.. but there is no rush.
    I have downloaded all the Workshop manuals, set up manual etc from Australian CX500 & 650 register... and have been looking on the other forum.
    Way too many Cafe Racer conversions in there for my liking... but good info all the same.
     
  6. Murdo

    Murdo The Good Doctor Premium Member Contributing Member

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    Nice one Andy, enjoy.
     
  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Hmm looking at the tyres they are going to need to be changed... both front and rear are 2014 tyres and have some minor cracking low down in the sidewalls... apart from that they are hard as a rock.
    As much as I have an aversion to a tyre called Shinko that seems to be the best compromise in available sizes to suit this bike... It is more a Cruiser and really will not be hustled along so a new set of Shinko's will work.
     
  8. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Not sure what the Club inspector will think of a 10 year old tyre but it would be a shame to scrap the front one as it is basically brand new.
    Never been round a corner by the look of it.
    [​IMG]
    [​IMG]


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  9. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    While checking the Maggot over to ensure it will pass the required checks for historic rego I found that I had no front parking light or tail light... headlight works fine both high and low beam...
    Then I checked to see if they worked on thw "P" position on the ignition.. and the tail lights work but still no parking light.
    Very strange... so off comes the headlight and I find the connection for the front parker has come adrift of its receptacle and it is too fiddly to try and repair it...
    But that still didnt remedy the lack of tail lights when ignition is on.. so after spending an hour or so colouring in wires on a wiring diagram and head scratching I thought I would just check the fuses... YEP... a blown fuse...replaced it and now I have power to the tail lights and front parker (when I get one) when ignition is on and lights are on.
    The headlight isnt one from a Honda (I think). Honda have a push in parker lamp (rubber bung holds the bulb) and on searching the item I need appears to be from a BMW.... thanks to @2valve for steering me to a good BMW parts outfit in WA.. the item will be here next week and that should sort out the headlight.
    Interesting thing I found is that quote a few models in the CX range had a lcking cover over the fuel filler... but.. it was kind of a dummy lock. Any key, screwdriver etc can open it.
    I was told the key was broken off inside it so I grabbed my lock picking kit... um broken key extraction set... sorry, and started to see if I could get the sucker out... when all attempts failed I found my cheap chinese borescope thingamabob and had a good close look... nope... no key in there.
    So that cover will go back on now as well.
    And finally today... I took a pic to give some perspective of ethe difference 43 hears has made to bikes..
    1983 CX500 rear end and 2022/23 Triumph TS660 rear end... the tyre is much wider on the RS660 but weight is similar, power is similar, riding position is vastly different (foot pegs are so high on the Honda) and I have to say... the Honda makes a much nicer noise :) Even with stock mufflers. I wonder how a set of Emgo Dunstall copies would sound... :)

    IMG_8111 (1).jpeg
     
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    Last edited: Sep 29, 2024
  10. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Well I have more pics but I am getting the 403 forbidden message... GRRRRRR
     
  11. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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  12. Murdo

    Murdo The Good Doctor Premium Member Contributing Member

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    Yes, the CX has a tail light and blinkers that the 'noddies' in thier tin tips can see (maybe) and I would bet the tyre is cheaper to replace too.
     
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  13. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Most likely, although choices will be a lot less on tyres now.


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  14. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Well I finally got around to removing the front cowl for prep and paint... Honda certainly didnt make life easy with the amount of wiring in behind the headlight. and the neat fit of the instrument cluster etc.
    Anyway, the paint match is quite close (the bike isnt a factory Honda colour) and is good enough as the cowl doesnt touch any other painted item. 3 good coats of DNA Custom Clear on it an it looks pretty good.
    The headlight issue (park light) was solvedd easilly. a BMW motorcycle part fixed the issue and a new 10 amp fuse.
    Reassemble was interesting, re wrapping the different parts of the loom so they could go where they were meant to in the headlight was a challenge, even with a drawing of how it should look in there but once it was done it all fitted in nicely and the headlight went back on far easier. Next step is a service... I might get to it today but we have massive storms around and 50mm of rain expected... so I will see... might even put new oil in the front forks.
    Then pink slip and Club rego :)

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  15. 2valve

    2valve Well-Known Member

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    Looking good there Andy , you've done well colour matching the paintwork.
    There pretty easy to service so i remember , and no drive chain to adjust !.
    How did you go with the tyre's in the end ?.
     
  16. gyro gearloose

    gyro gearloose Active Member

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    i get this a lot if i have another window/tab open and signed into that evil site with the two g's and o's..
     
  17. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Today was the day for an oil and filter change... drained a bit over 3 litres out so there was definitely fuel in the oil.
    Interestingly when I went to dispose of the old oil (responsibly of course) the spring that was meant to be at the back of the filter was in the oil catch tray...as the filter is still in the housing... thats not right.
    This means the filter I threw away had really just been soaking in oil... nothing had been filtered through it.
    So, new filter with the spring and a copper washer (all I had in the correct size) all assembled as per factory. New oil in and start her up. It sounds much better than it did and revs a bit crisper as well.. mind you these are not a super responsive engine at the best of times.
    I also 3D printed some locating bushes (I found an STL file on Thingiverse) for the side cover top mounts. Only 1 side had any and they were bretty knackered.
    I only had the "blue" TPU filament and they didnt print real well as I dont have a dryer for the filament.. apparently TPU really needs a Dryer (bought one on Amazon once I found out and some black TPU as well) but they fit and actually do a good job.
    I also painted the Fuse cover but it needs to dry before it goes on...
    Next step is Pink Slip.

    https://youtube.com/shorts/-2tZBLBuH5U

    The oil is swirly... due to the fuel seperating out a bit I guess.
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    Even has the original Factory tool kit
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    Original locating rubbers
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    New TPU ones installed
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