Honda CX500 update; crash bar and radiator plate

During continued electrical testing (cdi, stator, rectifier, etc), I'm also order some items from ebay and local shop. And installed to the plastic maggot, here the pictures.....

New (not really new ...order from ebay.uk) crash bar, radiator shroud and new Yuasa battery ...... perfectly fit  :-)

Picture from another side:

Honda CX500 update; Electrex Stator

Actually I did this update at 2009.
After some internet studied, I bought G47 stator from Electrex UK. I have very limited reference for my CX500, this is the only one CX500 in my country...., just guess my CX is a A or B type.

The Electrex G47 stator arrived on time, in very nice package......

And I start to dismantle my engine..........
Oooooppppss.................
The stator looks difference in shape and wiring.......

Any  idea, what type of CX500 is that?.....

MAXXIS Trepador for my ZJ Jeep

After upgrading my Grand Cherokee ZJ Jeep suspension (I haven't wrote it yet.......next post), including lifting my ZJ suspension 3", the next thing to do is replacing my old Dunlop Grantrek A/T with something M/T. I'm almost out of budget, so I can't effort BF Goodrich M/T KM2, too expensive. My options are: Bridgestone Dueler M/T, GT Radial Savero, Kumho (I'm not sure about quality), Federal Couragia and Maxxis Bighorn or Buckshot Mudder. Most all the time I'll use this car for on-road driving (80%), and once a month go for camping or adventure off-road  in the mountain. Due to my limited budget and space, I can't prepared 2 set of tires.


I'm familiar with bridgestone dueler M/T, the quality is good, and I'm also satisfied with its performance in dirt road.In tarmac and concrete road, ....hmmm noisy, and the model looks so old.. Federal Couragia is a new model available in Jakarta, however only few shops sell this tires, the tread pattern really impressed me, even though I don't know yet how its performance in dirty road or muddy road.

After visiting one tire shop who sell bridgestone and GT Radial, next destination is Maxxis tire shop. Actually I'm looking for Maxxis Bighorn or Buckshot Mudder. Bighorn tread pattern looks aggresive, and the buckshot looks very similar with Bridgestone M/T. Then my eyes stuck with Maxxis Trepador Radial, the tread patter really impressed me. Here the picture:

well, ....how do you think?
The price slightly higher than Bighorn, ......according to the seller, this Trepador is more silent in asphalt road than bighorn or buckshot mudder.
This Trepador also have better grip in muddy road compare to Bighorn.

Here the factory description about Trepador:

• Unique tread element arrangement ensures a uniform tread contact area for sure-footed handling.
• Multi-stage staggered shoulder pattern provides improved control even on the most difficult off-road and rocky terrain.
• Nylon belt-reinforced tire construction improves puncture resistance and prolongs tread life. 

So....., I choose Maxxis Trapador for my ZJ Jeep, the size is 31" x 10.5 R15. It cost Rp 1.450.000,- for each (approx. US$ 157)

 




































How the Trepador performance for daily use?..... I'll post the my experience with  Maxxis Trepador next month.

ZJ Project: front drive shaft replacement, CV to U-joint

As stated in many web sources, the front drive shaft ZJ jeep, Constant Velocity joint type (CV joint) is one of the ZJ weakness point, is easily broken, especially in off road daily used. It also happen with my ZJ, the CV joint start to wobbling, especially while driving above 60 km/m. This CV joint is not fixable, one its broken, you should replace with a new one, which is cost you around 350-400 bucks, and the same problem will come again after few years.

After some discussion and internet research....:-), I went to workshop and they offer me to replace the original CV joint with used Universal joint taken from cherokee country. They said that U-joint will fit properly in ZJ jeep. I saw many broken ZJ CV joints in that work shop, that mean my ZJ was not the first one. It cost only around $125 including installation cost.
Here some pictures of it:

1. broken CV joint

U-joint front drive shaft, taken from cherokee country (looks dirty...and not good...:-) ...).

The U-joint have been installed in my ZJ, just fit......

Add 3cm tire spacer to my Grand Cherokee ZJ

Last year I added 3 cm spacer to my grand ZJ, the main function of this spacer is to prevent the front tire (installed with 31" tire) rubbing the lower control arm when turning. The other function..... made the ZJ looking better...he...he, depend on your taste.....

The installation is simple, less than 30 minutes for all tires. Why only 3 cm? Because 3 cm is thick enough, strong enough, not easy to brake. With 3 cm spacer will not affected the wheel axes, minimized pendulum effect (compare to thicker spacer) and no need balancing before installation.

So, my front tire not rubbing lower control arm after I installed the 3 cm spacer, however..... a new problem rise, the front  tire rubbing the lower part of plastic bumper when turning......he....he, just cut it a little bit.

My Grand Cherokee ZJ problems.

My Grand Cherokee ZJ spec (2009 status):
Manufactured : 1998 (the latest model)
Engine : 4.0 litre I-6
Trim : Laredo
Modification :
- lift 2”
- 31” tire
- After market shock and coil springs (OME)
- After market sound system.

List of problems and solutions:

1. Front ring and pinion failed at 9,000 km. Symptom: noise from front differential. Solution: change the ring and pinion with the higher spec. This problem was common for latest version of Grand Cherokee ZJ.
2. Air conditioner evaporator leaking at 25,000 km. Symptom: lost of refrigerant, AC not cold as used to be, the compressor clutch on and of frequently. Solution: inspect the evaporator, clean it. Found a big hole in the evaporator, could not be repair, then change the evaporator. Note: the evaporator made by Zanden, the size is relatively small compare to ZJ interior volume. The evaporator was located under the dash board, to uninstall it you need to remove the dashboard first.
3. The master power window and central lock (on driver side and later all doors) failed. Symptom: completely failed, no button functioning. Solution: 1. Check the 30A fuse on the power distribution center under the hood, take it off and then put it back again. Usually the power window will work again normally. For better solution: make an on-off switch between the power window and the fuse, and turn off the electric charge when it not functioning. It is a common problem in Grand Cherokee ZJ, a continues electric supply to the central power window and central lock unit can make the system failed. 2. If the central lock still have problem, check the actuators, and replace it. If the original cost you a lot, find the after market central lock motor, its really cheap (made in china :-) ), around US$ 10 to 12 each and can work at least for 3 yrs.
4. Air Conditioner compressor failed at 38,000 km. The symptom almost the same with number 2, however usually the AC works fine at the beginning and failed after 1 hour trip (when the compressor reach its normal work temperature). Solution: Inspect the AC compressor, check for leaking. In my case, I open the compressor, overhaul it, and found most of the piston have been scratch badly, and some parts of the clutch have been damaged. I change the compressor completely. Note: My original compressor brand is Nippon Denso (ND), it is weird because the evaporator is manufactured by Zanden.
5. Transmission high pressure hose leaking at 47,000 km. This is the high pressure hose from the tranny to oil cooler, leaking on the oil cooler side. Symptom: oil leaking and then dripping from the hose, loosen transmission oil, when the condition become worst, the automatic gear can jump suddenly to neutral in normal driving condition. Solution: change the high pressure hose, add the transmission oil. Note: to check your ZJ transmission oil level, park your car in flat area with engine running, move the gear lever to N and check the level using a dip stick.
6. Engine misses throughout driving speed range starting at 51,000 km, the jeep engine misses in high rpm (i.e. above 2000 rpm). This problem occurs especially when driving a long trip. Solution: clean up the fuel tank, clean the fuel pump. Replace the fuel filter. Note: for my ZJ the fuel filter located inside the fuel tank, for pre 1998 ZJ, fuel filter located outside the fuel tank (more simple and easy to replace).
7. Death Wobble, occur several times after I lift my jeep 2” and changed the stock tires with 31” tires (see my previous post). Solution: proper wheel alignment. Note: after did a wheel alignment, the DW is gone, however the steering still not back to normal as an original setting, need more suspension up grade (see my next post)
8. CV joint front drive shaft is prone to be broken after few years, replace with Universal joint front drive shaft, taken from XJ country jeep or after market product.

The rest are minor problems, like death battery, dirty power window motor. Generally the I-6 engine is very reliable and low maintenance.
See my other post about my ZJ compare to the Japanese 4wd in Cars and Bikes site.

Lifting the Grand Cherokee to fit 31” tire.

To fit 31” tire in ZJ Jeep required body lift around 1.5” to 2”. There are plenty of suspension lift kits available in the market. Before lifting the jeep, please check the front drive shaft type, if your ZJ equipped with U-joint drive shaft, it is save to lift the body up to 2”, but if the ZJ equipped with CV-joint front drive shaft, please do not lift the body more than 1.5”. To gain 1.5” to 2” body lift, we can use:


Budget Boost / Polyurethane Suspension Lift.This is the cheapest way to gain 1.5 to 2” lift, just add polyurethane spacer on the top of the coil spring. Usually the spacers sold together with bump stop extension. For this method will cost around 60 dollar up to 150 dollar.

Change the suspension system with taller coil spring.There are many suspension products are available on the market, one of them is Old Man Emu brand (picture above) manufactured byARB. The Old Man Emu suspensions are not typically noted as a lift kit. They are usually regarded as suspensions systems. However, depending on vehicle weight and application, a lift of 1-1/2" to 2-1/2" can be gained. Many lift kits require a sacrifice of ride quality for off-road performance, but Old Man Emu is able to combine both to give outstanding ride quality with excellent spring articulation. Old Man Emu recommends using 31" tires for best performance. This suspension system will cost around 500 to 700 US dollar.

Combination of the above system.
This is what I did with my ZJ. After installed the OME spring and shock, the 31” tire still rubbing the fender. I suspect that the installation of the new OME spring and shock have not reach 1.5” lift as their claimed. So, I added ¾” polyurethane coil spacer (cost me 59 USD, bought from 4WD store) and the tire just fit, not rub the fender anymore. However, the tire still rubbing the front lower arm in the maximum turn position. To avoid this, we can add a wheel spacer or reduce the maximum wheel turn through an adjustable bold.
The pictures below showing the ZJ jeep with 29" stock tire and with Dunlop Grantrek A/T 31" new tires.

So what we got after installing 31” tire?
- Higher ground clearance
- Better look
- Plenty options of tire type (HT, AT, MT, super swamper, etc.)

Notes:
- Don’t forget to re-align the will after installing the lift-kit
- After one year using the OME system in normal road driving condition, I feel the shock absorber going weak, this is much shorter life than I expected. In near future I have aplan to change the OME shock with Pro Comp which is much cheaper with almost the same quality. 
- Further observation, actually the shock wasn't weak, but the bushing start to worn due to change of suspension geometry. This problem made the the jeep sway and some noise start.