80s Honda thumper generators

[guest1876]

I managed to acquire a Honda CB500RS via an ebay auction. It has an FT500 engine in a CB250RSD chassis, e-start removed and converted to kickstart. I'd like to change the L/H engine cover for a non e-start version. To do that I might need to change flywheels/stators etc. I can see this throwing up a number of issues, e.g. the 250 flywheel is lighter.

Can anyone tell me how much compatibility there is between the two systems? Can rotors/stators be mixed and matched?

[SteveC#222]

The Honda XL500 generator cover looks pretty similar without the electric start gubbins.

XL500


FT500


It might be a straight swap.  I think you need to find an alternative cover that fits first and then look at the electrics. Rather than buy an actual cover, you might be able to get cover gasket for the FT and potential donor cover and see if they match up.

[guest1876]

Thanks Steve.

I'm 99% sure they are the same at the gasket surface, but you can see that the FT item looks deeper which I think is to accommodate the e-start gear mounted to the circumference of the rotor. That's what leads me to think I may need to start swapping stators and rotors. Alternatively I could just remove/cut away all the e-start gubbins from the FT cover and have it blanked-off somehow?

Ken

[tevie54]

Everything from the CB250RS swaps over no problem

[guest1876]

Ah, thanks tevie54.

I'll start gathering bits asap!