CX500 / Trident Police Trike Rebuild

for those of you that have M.B.S. (multiple bike syndrome) and have the "silver wing" models.
as our sponsors also have supplies for those bikes and they are popular with the "wing" crowd.

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scootsx2
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CX500 / Trident Police Trike Rebuild

#1

Post by scootsx2 »

This is the start of my build thread for putting the Trident police trike back on the road.
IMG_3260.JPG
IMG_3260.JPG (90.03 KiB) Viewed 1226 times
The first order of business is to get the engine running. The fuel system is a horror show - the tank is filled with stuff that belongs at an EPA toxic waste site. Really ugly. I am 100% confident that the carbs are a horror show as well. I had contacted Howard Halasz (a Randakk recommended carb guru for CX500 carbs) and he basically declined the carb work. If I don't find someone else to do the carbs I will take a shot at them myself although I prefer they be done by a carb guru.

First thing I did was to verify that the engine wasn't seized. I removed the spark plugs and the crankshaft access cover and was easily able to manually turn the engine over via the crankshaft bolt. The rubber boot on the right-side spark plug was dry rotted (most of the rubber pieces are dry rotted) to the point where water had accumulated in the spark plug recess. There a boatload of corrosion in the recess. I blew out the accumulated crud and sprayed Kroil in there. After letting it sit awhile I was able to fairly easily remove the spark plug. There were a couple of small spots at the very top of the spark plug thread where there was a minute bit of aluminum from the head but close inspection showed the threads in the head looked pretty good. I was able to screw a new spark plug into the hole without any issues. The left side plug came out with no issues.

The work plan is as follows:

1) Clean the fuel system and rebuild the carbs.
2) Replace the throttle tube. The one that came on the trike literally crumbled.
3) Go though the electrical system sufficiently to get the starter and ignition working.
4) Change the coolant. Fix whatever leaks.
5) Change the air filter, oil and oil filter
6) Get the beast to fire up.

Once I get the engine running I will do several oil and filter changes followed by a cooling system flush and replacement of the coolant hoses.

7) Rebuild the brakes.
8) Go though the rest of the electrical system. This thing has a car battery rather than a bike battery. See the next post.
...
...
...
Stay tuned.
Left Side Sparkplug Hole
Left Side Sparkplug Hole
IMG_3961.JPG (88.67 KiB) Viewed 1226 times
Right Side Sparkplug Hole
Right Side Sparkplug Hole
IMG_3960.JPG (98.52 KiB) Viewed 1226 times
Right Side Sparkplug Cap
Right Side Sparkplug Cap
IMG_3968.JPG (117.55 KiB) Viewed 1226 times
Right Side Sparkplug Cap
Right Side Sparkplug Cap
IMG_3969.JPG (96.35 KiB) Viewed 1226 times
Last edited by scootsx2 on Sat Nov 26, 2016 9:40 pm, edited 1 time in total.
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike

#2

Post by scootsx2 »

The car battery. Probably needed to support the red lights, siren, radio, etc - lots of extra current draw. Hopefully the stator is OK.
IMG_3964.JPG
IMG_3964.JPG (98.9 KiB) Viewed 1225 times
IMG_3965.JPG
IMG_3965.JPG (93.75 KiB) Viewed 1225 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike

#3

Post by salukispeed »

Looks like the drain holes in the bottom of the plug wells are plugged. Same issue our goldwings have. Often destroy's the plug boots internals. The carbs are not that bad to do. A bit like our early wings. But only 2. Did not catch what year the bike is but the 80 and earlier have CDI ignition and can be troublesome. After many rotations with the crank bolt and If free and your comfortable with what you see you might crank the engine with the starter and fresh oil you can check for spark , Compression and oil pressure.
Honda 72 CL100 sold
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Re: CX500 / Trident Police Trike

#4

Post by scootsx2 »

It's an '82 under the covers.

If I can't find a reliable person to do the carbs I'll take a shot at them myself. I acquired copies of both Larry Cargill's and Mike Nixon's CX500 carb rebuilding manuals.

I plan to remove the fairing this weekend so I can get better access to everything.
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike

#5

Post by salukispeed »

make sure you have a good JIS screw driver and get your best rust buster for the screws on the carbs. Give it a day or more to work for those carb screws look very rusty and could be tough. A good rap on the screws can help. WD40 is not likely the best buster. If you use the 50-50 trans and acetone or KROIL is even better yet. Just dont break the screws. Take the time to get them to come loose.
Honda 72 CL100 sold
74 CB750 K4 nice driver
1966 CA77/305 Dream nostalgic driver
84 GL1200I work in progress
1970 CT 70
1982 GL500 Interstate
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Re: CX500 / Trident Police Trike

#6

Post by scootsx2 »

I know the drill - I brought my '75 GL1000 back to life about 6 years ago. Already have all the tools and I am a firm believer in Kroil. Good stuff.

The fairing is off. It's a Pacifico unit and is surprisingly light - only a few pounds. Also removed the seat and the tank. Need to spend some serious time cleaning it out. The petcock is not the original vacuum operated unit; it's a manual unit and is pretty well frozen, most likely filled with the same petrified gunk that's in the tank.

I discovered that the coolant overflow bottle is cracked but fortunately the PO had acquired a replacement so it's one less part that needs to be purchased.

I found some electrical "stuff" bundled inside gray fabric bags; one on the front forks (visible in a photo below) and one buried under the seat. I think it's stuff related to the trike conversion. Some research is in order.

I have been in contact with Larry Cargill who wrote one the the CX500 carb overhaul manuals that Randakk recommends. He will rebuild the carbs for what I consider a reasonable price. Some time within the next week I'll pull the carbs, box them up and send them off.

Looks like i'll probably be pulling the box of the back of the trike so I can get access to the battery and check out the state of the wiring and brake lines underneath. It will also make access to the grease nipples on the U-joints much easier.
Fairing removed
Fairing removed
IMG_3993.JPG (112.59 KiB) Viewed 1174 times
Naked front end
Naked front end
IMG_3994.JPG (119.82 KiB) Viewed 1174 times
Cracked coolant overflow bottle
Cracked coolant overflow bottle
IMG_3956.JPG (112 KiB) Viewed 1174 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike

#7

Post by scootsx2 »

I spent the last two days cleaning up the chassis and wiring harness, removing eons of road grime. Also sent the carbs off to Larry Cargill for rebuilding.

As I was doing some initial cleaning of the gummed up gasoline residue in the tank I discovered that the tank had been lined with Kreem and the lining was loose. In fact, I was able to pull HUGE sheets of Kreem out of the tank with my fingers (see the photos below). So, tomorrow I am taking the tank to a local industrial radiator shop that also works on fuel tanks and will have then properly clean and seal the tank.
Kreem lining. It's not really attached.
Kreem lining. It's not really attached.
IMG_4037.JPG (95.23 KiB) Viewed 1157 times
Kreem lining that came out of the tank
Kreem lining that came out of the tank
IMG_4038.JPG (151.04 KiB) Viewed 1157 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike

#8

Post by scootsx2 »

I removed the fiberglass box on the back of the trike to get better access to the rear end. The box was held on with 4 bolts through the frame. It only weighted about 20 lbs max and was easy to get off. There were two wiring harness connectors that had to be unplugged first. They appear to carry the wiring for the rear lights and for the siren - the siren controller is mounted inside the box.

I also removed the rear bag that enclosed some electrical components. It contained two relays and the controller for the flashing lights.

Now that the rear box is off, it became apparent the the trike is a hardtail. This explains the small coilovers under the seat. The rear box mounts on a subframe which is sprung on a pair of KYB coilovers. Tracing down the rear brake lines also showed that the hydraulic parking brake only operates on the right rear wheel.
The rear box has been removed
The rear box has been removed
IMG_4054.JPG (94.06 KiB) Viewed 1140 times
Stripped down to the frame
Stripped down to the frame
IMG_4058.JPG (118.04 KiB) Viewed 1140 times
It's a hardtail
It's a hardtail
IMG_4056.JPG (116.68 KiB) Viewed 1140 times
The gray bag containing relays and flashing lights controller
The gray bag containing relays and flashing lights controller
IMG_4061.JPG (130.02 KiB) Viewed 1140 times
Parking brake control on right side
Parking brake control on right side
IMG_4062.JPG (104.78 KiB) Viewed 1140 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#9

Post by scootsx2 »

Today I received the carbs back from Larry Cargill. I don't think he understood the intensity of the horror show that is this bike's fuel system. Direct quote "... this set has been the most problematic set I have ever encountered in the 10 years I've rebuilding these carbs." It's not just a horror show, it's a double feature horror show.

Long story short, Mr. Cargill performed magic and then some. These carbs look like they are from a new bike. I'll reinstall them after I get the electrical system working sufficiently to crank the engine and get spark... probably some time in the next 2 or 3 weeks.
IMG_4101.JPG
IMG_4101.JPG (159.87 KiB) Viewed 1118 times
IMG_4103.JPG
IMG_4103.JPG (122.81 KiB) Viewed 1118 times
The gas tank is out at a local industrial radiator shop that also works on fuel tanks. They made similar comments about the tank (see the previous photos of the tank). They estimate getting the tank back to me on or around 23 December.

I started work on the electrical system. The battery was history so it became a core trade-in for a new battery. Sidepost batteries currently available have screw-in terminals instead of heavy lugs so I changed the ends on the battery cables. Then started working my way further into the electrical system. Discovered two starter solenoids on the bike; the "normal" solenoid for the starter and a 2nd solenoid that had a very lightweight wire, perhaps 16 AWG, on it's output terminal. I have no idea what this is for yet - maybe something for the trike conversion. There is corrosion everywhere in the electrical system. The cable connectors don't seem to be too bad but I may replace a few if the terminals appear burned or loose. I sourced a replacement ignition switch because the original one was frozen. Also picked up a new fuel petcock (the old one was petrified), ordered a replacement starter solenoid because I don't trust the original to be reliable (see photo below) and a replacement for one of the spark plug boots. The internal resistor was frozen in position. I managed to loosen it a bit by soaking with Kroil but there appears to be no spring tension behind the resistor. Last thing I need is an intermittent connection in the ignition. Later this weekend I'll pull the coil packs and check them over and also work on freeing up the throttle grip on the handlebars. It's a real shame that the PO didn't store this bike properly.
IMG_4089.JPG
IMG_4089.JPG (117.28 KiB) Viewed 1118 times
IMG_4088.JPG
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IMG_4094.JPG
IMG_4094.JPG (120.36 KiB) Viewed 1118 times
Last edited by scootsx2 on Sun Dec 18, 2016 11:37 am, edited 1 time in total.
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#10

Post by scootsx2 »

The twist grip and right handlebar switch cluster were pretty well frozen up from corrosion. I removed them to work on the switch cluster in my shop and to replace the throttle tube.
IMG_4122.JPG
IMG_4122.JPG (83.22 KiB) Viewed 1097 times
The trike didn't come with an ignition switch key so I replaced the ignition switch with a Taiwan clone part. I had to remove the instrument cluster to get access to the ignition switch. One of the two mounting bolts sheared off with little effort applied (may have already been stressed) even though I had soaked them for a l-o-n-g time with Kroil. Damned corrosion again. I'll drill it out and retap the hole.
IMG_4132.JPG
IMG_4132.JPG (116.69 KiB) Viewed 1097 times
IMG_4133.JPG
IMG_4133.JPG (127.01 KiB) Viewed 1097 times
I also pulled the coil pack. Preliminary inspection shows a small crack at the base of one of the coils. The crack shows up white in the photo due to the flash. It's a crack, not a scratch. Hopefully I can get enough spark to fire up the engine in the next couple of weeks. I'll keep an eye out for a replacement coil. Sealing the crack with epoxy would be a half-assed solution since it would seal in any corrosion and/or moisture.
IMG_4135.JPG
IMG_4135.JPG (120.87 KiB) Viewed 1097 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#11

Post by scootsx2 »

I have ordered a pair of replacement coils. They should be here any day. This evening I replaced the throttle tube and both throttle cables. The mechanism is nice and smooth and the switch cluster works perfectly. Also replaced the starter solenoid and reinstalled the rectifier/regulator. I checked the stator and it appears OK. Uniform resistance (~ 0.5 ohms) from wire-to-wire and no continuity between the windings and ground.

I need to pick up a 30-amp fuse and holder to replace the fusible link. Then I am very close to trying to get the engine to crank with the starter - maybe this weekend.
New Throttle Tube and New Throttle Cables
New Throttle Tube and New Throttle Cables
IMG_4151.JPG (103.59 KiB) Viewed 1082 times
New Starter Solenoid
New Starter Solenoid
IMG_4152.JPG (145.16 KiB) Viewed 1082 times
New Battery Cable Connectors
New Battery Cable Connectors
IMG_4153.JPG (143.74 KiB) Viewed 1082 times
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#12

Post by desertrefugee »

Just checked in on this build. You have my attention. (And you're giving me some motivation to make time to get back to my sidecar rig).

...but this Police trike is really neat.
- Life is not about waiting for the storms to pass. It's about learning to ride in the rain.
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Re: CX500 / Trident Police Trike Rebuild

#13

Post by scootsx2 »

I spent most of this evening cleaning up various electrical connectors and ground connections.The engine cranks very nicely!!!! Life is good.

Next steps are to get the carbs and coils reinstalled over the next couple of days, hook up an auxiliary fuel tank and see if I can get the engine to fire up.
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#14

Post by scootsx2 »

sparkplug.jpg
sparkplug.jpg (2.96 KiB) Viewed 1033 times
I spent most of the afternoon working on the ignition and now have spark to both cylinders.The left side had spark on the first try. The right side had two issues:

- A new NGK D8EA sparkplug was bad. There was no continuity between the threaded rod at the top of the plug and the center electrode. I have never encountered such a failure before.

- The coil was bad on the secondary side. This is the coil that had a crack in the case (see one of my earlier posts). I had purchased a set of good used coils on Ebay and simply swapped out the coil pack.

A very good resource for troubleshooting ignition problems specific to these bikes is a document available at:
http://www.genebitsystems.com/david/Mot ... oblems.htm
1975 GL1000 Sidecar Outfit
1982 CX500-based Trident ex-Police Trike
2001 GL1800 MotorTrike
2006 Vespa LX150
1956 Francis-Barnett Falcon 74
195x Solex 1700
196x Solex 2200

St. Louis, MO

The dude abides.

Brothers of the Third Wheel - Gateway Chapter http://www.btw-trikers.org
Vintage Japanese Motorcycle Club http://www.vjmc.org
Francis-Barnett Owners Club http://www.francis-barnett.co.uk/
Antique Motorcycle Club of America http://www.antiquemotorcycle.org/
Vintage Motor Cycle Club http://www.vmcc.net
British Motorcycle Charitable Trust http://www.bmct.org/
VeloSolex Club UK http://www.velosolexclubuk.com/
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Re: CX500 / Trident Police Trike Rebuild

#15

Post by 05c50 »

scootsx2 wrote:sparkplug.jpg
- A new NGK D8EA sparkplug was bad. There was no continuity between the threaded rod at the top of the plug and the center electrode. I have never encountered such a failure before.
That's very unusual. NGK spark plugs are a quality product, but there are some counterfeit ones being sold. Take a look at this information. It will show you how to verify if you have the real or fake item. http://www.ngk-sparkplugs.jp/english/techinfo/fake/

.....Paul
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My wife asked me "How many bikes does one man need?" My answer "Uhhh.just one more"
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80 CB650c
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