Author Topic: 1972 CB500 "Modern Cafe" Build (Read 14012 times)

Trevor.resar · « **on:** January 31, 2012, 07:58:15 PM »

So after a friend of mine showed me a few Lossa Engineering bikes, and several days later I saw a re run of Cafe Racer on TV, I decided to take a step away from my "everyday" rider (2009 CBR1000rr) and find a project. I have been very intrigued by Bryan Fuller's CB750

Taking inspiration from his bike, I want to modernize an older bike. New style swing arm, mono shock, disc brakes, newer style wheels, etc, etc.

That is where this beauty comes into play.

A 1972 Honda CB500. Owner was asking $800, ended up taking it home for $350

Couldn't wait to start the project, I actually started tearing it down at 11pm, before I got it out of my truck

I went into a research frenzy trying to find out what size, and style of swing arm would best fit my frame. Turns out the Honda CBR F2 rear end has the same size width at the frame as the stock swingarm.

Luckily a local motorcycle salvage yard had just got a F2 in. I snagged everything from the swingarm back for $150

This is it mounted

I'm now in the process of fabricating a mount for the mono shock, and relocating the wiring, battery, and fuses.

rb550four · « **Reply #1 on:** January 31, 2012, 09:08:39 PM »

Great inspiration photo. Sounds like someone was jonesin for a project, didn't even get it off the truck before it was stripped! Somebody else do the driving while you did the stripping or perhaps you' re a multitasker that can handle a truck with one hand and a socket set with the other. That was funny as hell, I share that kind of excitement whenever I get a bike. Bet ya couldn't get that seat off fast enough ,right? And how lucky is this that there was the exact swingarm you needed was right there ? Looks like your project is well on it's way,what do ya think, will it be finished next week? just kidding. I'd like to keep up with this build looks like fun.

luap · « **Reply #2 on:** January 31, 2012, 09:29:49 PM »

gonna be cool, I like those finnned tappet covers, If those arnt gonna be used in your build let me know

dirty rat · « **Reply #3 on:** February 02, 2012, 02:14:36 AM »

it should handle good

wedoo2 · « **Reply #4 on:** February 02, 2012, 02:31:54 AM »

At the rate you are going this may be the shortest build thread yet. I love Fuller's bike, so clean. One thing that stands out is the CB836F decal on the swingarm. It makes me think about a square one just to do that. I understand the myopia you get on these builds. I got up at 3:30 the other night to work on the bump on my seat. It's a sickness.

Trevor.resar · « **Reply #5 on:** February 02, 2012, 09:06:32 PM »

Pulled the carbs off today, and was actually surprised. Not nearly as bad as I thought they were going to be.

Any thoughts as to what I need to do to get them and the engine case black? Cost affordable?

Tews19 · « **Reply #6 on:** February 02, 2012, 09:14:14 PM »

Nice project you have going there. a suggestion is to clean the carbs first then polish the float bowls and tops of the carbs. I did this and they look great polished. Any improvements to the front end of the bike? How many teeth does the rear sprocket have? Can we see a full pic of the bike with new swing arm on?

dirty rat · « **Reply #7 on:** February 03, 2012, 02:24:16 AM »

those carbs look good trevor ive seen some horror pictures posted of the same type of carbs with like water or what not in them

Trevor.resar · « **Reply #8 on:** February 03, 2012, 07:15:40 AM »

Still working on what I want to do with the front end. The current forks that are on it are trashed. When I was strapping the bike down, the fork seal boots fell apart from being so old. I was told by the previous owner that these forks were an after market deal. More of a rake to them, kind of chopper style. Not my style.

I'd really like to do something similar to what I did on the rear end of the bike. I just have no clue what forks would work for me from a newer bike.

Tews19 · « **Reply #9 on:** February 03, 2012, 07:33:13 AM »

Quote from: Trevor.resar on February 03, 2012, 07:15:40 AM

Still working on what I want to do with the front end. The current forks that are on it are trashed. When I was strapping the bike down, the fork seal boots fell apart from being so old. I was told by the previous owner that these forks were an after market deal. More of a rake to them, kind of chopper style. Not my style.

I'd really like to do something similar to what I did on the rear end of the bike. I just have no clue what forks would work for me from a newer bike.

I think those are the dust covers that may have crumbled. If you are going modern front end. Check out fun jimmy build. I am pretty sure you can do a bolt on from an r1 or r6 front end without much modification. I am thinking a guy in south florida did a direct bolt on front end from a yzf? Not sure if that sounds correct but I can look into my notes.

Did you hear the engine run? Hate to see all this work go into the bike and have a dead engine............ Here is a pic of my carbs before and after a simple clean and polish....

Trevor.resar · « **Reply #10 on:** February 03, 2012, 08:10:46 AM »

Wow they do look really good polished. I may end up going that route.

Personally, I haven't heard the bike run. He assured me that it ran 6-7 months ago, he just needed to sell this bike to get his cb550 running again. Wether or not that can be believed is suspect. The spark plugs looked great, and had good compression in all of the cylinders. So I'm not too scared that I can't get it running.

The R6 forks may be worth looking into. Those bikes are a dime a dozen around here at salvage yards. I'm assuming I'd just use the triple tree from the R6 too. Just have to press a new bearing into the neck of my frame?

Also, who do you guys use for small parts such as carb rebuild kits? I've looked a little online, and all I've found are small websites that seem a little questionable.

Tews19 · « **Reply #11 on:** February 03, 2012, 08:29:55 AM »

bearings.........go with tapered from All Balls.

There are modifications with all modern set ups. Use the search button on main page.. Also search funjimmy build.....

Trevor.resar · « **Reply #12 on:** February 04, 2012, 10:05:36 AM »

This is the float bowls and the tops of the carbs. They cleaned up pretty nice.
Before:

After:

I started with Chem-Dip, and honestly it did 90% of the work. The gallon jug comes with a dip basket, 15-20 minutes for most of the parts, and over night on the Bowls

A little hint, when you have items submerged, place the lid back on top. This stuff evaporates very fast, even though it is very thick.

After the dip, I washed them in my parts cleaning bay

And finished them off with a wire wheel and polish pad

FunJimmy · « **Reply #13 on:** February 04, 2012, 02:34:17 PM »

Quote from: Trevor.resar on February 03, 2012, 08:10:46 AM

The R6 forks may be worth looking into. Those bikes are a dime a dozen around here at salvage yards. I'm assuming I'd just use the triple tree from the R6 too. Just have to press a new bearing into the neck of my

R6 forks are a snap to install.
Early ones have a bit more offset than later.

FJ

Flick · « **Reply #14 on:** February 04, 2012, 03:46:51 PM »

MONO SHOCK!! That's awesome, cool build...

wedoo2 · « **Reply #15 on:** February 04, 2012, 04:46:06 PM »

One thing I might suggest is when you get seals for the bowls, try to find some that are in the shape of the bowls. The round ones are a PIA.

FunJimmy · « **Reply #16 on:** February 04, 2012, 05:29:55 PM »

Quote from: wedoo2 on February 04, 2012, 04:46:06 PM

One thing I might suggest is when you get seals for the bowls, try to find some that are in the shape of the bowls. The round ones are a PIA.

Who sells a shaped bowl seal?
I've only ever seen round ones.
If you have round seals use a dab of Hylomar to hold them until the bowls are fitted.

FJ.

Trevor.resar · « **Reply #17 on:** February 09, 2012, 03:21:11 PM »

I hit my first speed bump today. The company I ordered my Carb kits through, sent me the wrong kits. So I took the extra time I had to clean up the carbs more thouroughly today.

And after several Dremel hours later, this was the finished product:

cmonSTART · « **Reply #18 on:** February 10, 2012, 11:39:33 AM »

What type of bits did you use for your Dremel?

Trevor.resar · « **Reply #19 on:** February 10, 2012, 03:25:57 PM »

These are the ones I'd recommend. The "SOS pad wheels" that come in the Dremel polishing kit are garbage. They just fall apart.

Save yourself some money and just buy the three pictured above

A quick tip:
When using these bits, try to keep all of your movement going one direction. If not, you'll end up with tool marks on your metal

cbfnut · « **Reply #20 on:** February 11, 2012, 01:07:00 AM »

I thought about doing a modern cafe with an old honda, but I didn't want to mess with the bike so much that I would throw off the geometry severely. I say this because I really don't have a lot of mechanical ability and would most likely end up sliding across the road leaving skin behind, again. But, I am really interested in how this is going to turn out. Have you thought about putting upside down forks on the front end? It will make the front end look really beefy, though. Might not be the look your going after, but I think it might be cool.

wedoo2 · « **Reply #21 on:** February 11, 2012, 03:47:59 AM »

Those carbs are shiny. I know how much work that is. Three to go?

Trevor.resar · « **Reply #22 on:** February 11, 2012, 07:45:11 AM »

After reading through Jimmy's thread, I think I'm going to go with R6 forks. Seems pretty straight forward.

And all 4 carbs are polished, just waiting on the rebuild kits to get here so I can finish this part up.

rhino8648 · « **Reply #23 on:** February 11, 2012, 10:54:26 AM »

Great job looks fantastic I'm also in the middle of my cb750k restore cafe project .I sympathize with all the man hours put into this ! But that gives you that much more enjoyment when you ride it !
enjoy my progress.....

lucky · « **Reply #24 on:** February 11, 2012, 11:44:52 AM »

Quote from: Trevor.resar on January 31, 2012, 07:58:15 PM

So after a friend of mine showed me a few Lossa Engineering bikes, and several days later I saw a re run of Cafe Racer on TV, I decided to take a step away from my "everyday" rider (2009 CBR1000rr) and find a project. I have been very intrigued by Bryan Fuller's CB750

Why is the seat so high up in the air? (Talking about Bryan Fullers Bike)
It just raises the center of gravity.
All that gas weight is way up high in the air too.

News:

Author Topic: 1972 CB500 "Modern Cafe" Build (Read 14012 times)

dirty rat

dirty rat