Author Topic: project 1 of12 started (Read 33645 times)

Mcwilliams570 · « **Reply #75 on:** April 09, 2012, 02:53:38 PM »

I enjoy looking at all your project that you have going on. I would love to have the space that you have for your bikes. Here is a picture of my garage err shed just for giggles I can get 6 bikes in there when I have to..Keep up the good work..

Matt

rb550four · « **Reply #76 on:** April 10, 2012, 07:18:23 PM »

That's a nice space, it may not be everything that you wish it could be but , I see that doesn't stop you from building a nice bike or house other very nice machines. I've been following the Screaming Scotsman thread, you know how to work that space and it's coming out nicely. I see a few guys only have a driveway and a dream and that can be motivation enough to get it done. We're the lucky ones, to have a piece of earth that we can work on classic motorcycles.

rb550four · « **Reply #77 on:** April 13, 2012, 08:00:01 PM »

Well it's been more than a few days since I left the last 2 500 motors hanging from the rafters like a side of beef. No change, nasty looking partially eaten pistons drenched in everything and still the weight of the gearbox hasn't budged the pistons or the position of the jug.I've decided to attack these motors full on with an air impact tool with and 1 1/4 socket upsidedown on the pistons.Three hours later the jug was the only thing hanging from the 1 st motor.The gearbox and lower end seem good so I'll take it apart, replace both chains get some pistons, an get the cylinders bored.put this one in the last project frame . will probably breakdown the last 500 motor ,go through the gearbox and bottom end, paint it ,shove it in a bag and save it should one of them go south .

I just have to start on those 550's and rebuild all of those carbs, perhaps I should stay off the computer for a while and get something done in the garage.
I'm wondering about pistons, can't decide, go new aftermarket or go ebay used . Not sure if there is a real benefit to go with new, any thoughts?

rb550four · « **Reply #78 on:** April 14, 2012, 06:41:00 PM »

Okay, so I put the engines on hold until I make up my mind about those pistons. But I did order the timing chain and primary drive chain. Bored with motors right now so, I decided to dismantle the 77 550 k, the one that used to have the fairing and all those damn fiberglass boxes. I keep seeing members looking for intake boots, I only use pods so there is a complete airbox and boots that will just sit on a shelf with the rest of them until I get tired of looking at them so, if you need an airbox w/ good gaskets and boots, let me know.

rb550four · « **Reply #79 on:** April 16, 2012, 06:38:30 PM »

I took the day off so I could work on that 77 K but, it was 90 degrees so I took my wife (her day off) for a nice long ride on the 650 instead.
Can't be wrenchin all the time and expect her to like it if I don't give her a ride once in a while right?

rb550four · « **Reply #80 on:** April 18, 2012, 05:17:20 PM »

Got into the garage after work and walked right past the 77k. Walked over to the 500 project with the orange tank that has been a roller with a a rebuilt in the cradle. The green drowned 550 that was in need of rebuild became the donor .

All the electrical parts and wiring harness got a good cleaning and was installed on the 500, as was the clubman bars, the cafe 500's original tank, split level seat,early blinkers,new header,and anything else that was spare on the shelf and by 11 o'clock it's looking like a motorcycle again.Just have to get done cleaning the carbs and fire it up,tune and sync. That'll be one project done except for some painting when it gets warmer. Now that I feel like something's getting accomplished around here and a pile of parts are out of the way, it's 550 time. I still have a very stubborn seized 500 engine hanging from the rafters that can wait a little longer.

rb550four · « **Reply #81 on:** April 18, 2012, 05:31:57 PM »

I'm thinking that that 550 k needs a paint job for sure, I was thinking I'd shoot some metallic maroon basecoat /clearcoat so it would look as stock as possible but I've been seeing a '12 Focus around that has this really nice metallic type limey green color that could look really nice but I don't know if it would look too Kawasaki?

rb550four · « **Reply #82 on:** April 20, 2012, 06:38:27 PM »

Last night I found a guy parting out a 78 k with low miles. Bought running motor,entire wire harness,tank seat,and carbs. He wouldn't sell the bike whole, thought he could make more taking it apart, when I asked him about the frame, then looked at the motor with everything on it, then I asked how he got the motor out, sawed it out. On a titled frame, he saws the motor out.

On a happier note the 2nd 500 rolling project with freshened engine now has an upgraded complete electric system. the tank is the orange one that has been swapped with the last 500 project. The tank from the 78 k is in fine condition so it may end up on the 77k along with the seat.

Tews19 · « **Reply #83 on:** April 20, 2012, 06:50:04 PM »

Keyed Ignition wIth it? How the hell you keep coming across all these bikes?!

rb550four · « **Reply #84 on:** April 21, 2012, 09:11:17 PM »

Yes tews19, it did come with a factory keyed ignition, I have no aftermarket K ignition switches here so I incorporated it with the original harness. If I were to come across a keyed factory switch ,which are you looking for, the 4 wire F or the 5 wire K ?
Does anyone here have experience with a PD set of carbs on a 500 motor? Yes it has pods, and non factory exhaust 2into1 twice. Thinking a re jet is +4 from stock size, is that the way to go? I backed off the air a half turn , helped only a little. Runs like a SOB on full choke , figured too much air. Need input please. And I did switch to the proper intake manifolds.

rb550four · « **Reply #85 on:** April 22, 2012, 01:00:22 PM »

Thanks for the PM Lucky, The PDs are coming out and the other ones are going back on.
I've watched Lucky tune carbs allot on this forum, if he says you can't tune them (with pods)- you can't tune them.

Tews19 · « **Reply #86 on:** April 23, 2012, 06:39:30 PM »

not sure what lucky all said about PD's but he should have mentioned they are a PITA!! Any more pics of your work RB?

rb550four · « **Reply #87 on:** April 23, 2012, 07:07:03 PM »

Pics coming up next sunny day. The last rolling 500 is up and running!
Went old school ,fresh points and condensers. I've been done the last 3 with Dyna S electronic ignition, too easy.Just have to sync the carbs,take it for a ride, then take some pictures. The other 500 will run good once I get those PDs off it, have a different set waiting to be cleaned.Threw the new K tank on that one,really like it, looks like a custom seat is in order.
Anyone have an easy way to the get pad out of the caliper (piston side)?

rb550four · « **Reply #88 on:** April 25, 2012, 06:40:30 PM »

No really, this brake pad stuff is getting to me, tried soaking them in every toxic, volatile liquid in the garage, no good. Tried cooking them in lemon juice, didn't do it. The Works removed some rust around the pad,cooked them again and soaked them in PB blaster and they are still not coming out. I have been most fortunate only having this problem once before, and I drilled and tapped it out.....big PITA and it took all day.There has to be an easier way, I have 6 frozen ones on the shelf and 2 recently seized from flooding. Tried compressed air when hot and cold, no good. The next move may end up black powder and a stripped extension cord but , No one on this forum has mentioned the use of gunpowder and if that really worked I'm sure that there would be videos of it every week. What does everyone else do?

Tews19 · « **Reply #89 on:** April 25, 2012, 07:18:19 PM »

What do you mean pads are rusty? The back side and sides? If it that, Member mikekato helped me with this. I used my brass wheel on my bench grinder... Came out like new

rb550four · « **Reply #90 on:** April 26, 2012, 01:22:15 PM »

The backside or the pad is rusted and fused to the piston. I can't understand why there wasn't a built in failsafe for removal, like a threaded hole in the center of the pad through the backing plate where one could use and 8mm bolt to separate the two , it's not like they didn't know this would happen. And worse yet, replacement pads have not been improved to address this problem.
And I was kinda kidding about the powder, no one needs a grenade going off in the yard. I guess. but I do find myself wondering about a 22 cal. light load from my Hilti. Bad idea,Bad, Bad, don't try this at home kids.
Alright , so I'll try to clean them up a little more and try the greasegun.

rb550four · « **Reply #91 on:** April 29, 2012, 06:45:27 PM »

Okay ,so the worst 2 calipers in my shop was the first ones that I decided to do. Besides super rusty pad backing,cruddy sand like stuff, oxidized aluminum, they looked like they spent some time on the bottom of the Hudson River.The pistons totally pitted. The next six went along much, much smoother, in fact it was a pleasure. That left me with enough time to cook up some Carbs Smothered in Lemon Juice, so nice.
The carbs are all back together and going to be switched out with a last years clean carb that I stuck in the 500, #2 suffers from leakage and has to come off anyways,I'll do the polish trick and put it in the next 550 and see if it 's okay enough to run this season. Yeah , it's the metal type needle without the rubber end that Lucky warned us about.

rb550four · « **Reply #92 on:** April 30, 2012, 07:01:15 PM »

I checked on ordering 2 caliper pistons since 2 where wasted and it would be nice to have a ready set or two on the shelf. No go on the pistons from Honda. My guess is that somebody somewhere makes them ,if not I'll get them made at my local machine shop.
There's 6 master cylinders on the shelf that need rebuild, did order 2 kits.
Put the freshly rebuilt carbs into the 500 that was having a piddling issue in carb#2, runs much better , left a note on it "needs to be sync'ed." If I didn't I'd end up resync'ing everything in the place til I found the right one.

So, Ive reached that time in a man's life when you come to the "realization", it's an awful truth that makes most men shutter, my garage isn't big enough! If I get them all in and there's no room to work, if I take one out ,it has to be turned around outside and backed in. All the benches are full of motors and carbs and there's more of the same on the floor and in frames waiting to get on the bench. Holy cow! It's deja vu all over again.
It's been pretty dry so I think that I may take a chance and move this operation in town. I have a 45x 100 space there. It couldn't flood my bikes twice right?

rb550four · « **Reply #93 on:** May 02, 2012, 03:55:05 PM »

The above being the case , there is a 550 that I have agreed to purchase and take home on Saturday. It's a long ride so I'll look for another one to pick up on the way home.
Pics to be downloaded tonight after dinner.
I put a few pics on my photobucket album and I'm afraid that I'm not smart enough to transfer the images to this site.
http://s1170.photobucket.com/albums/r537/rb550four/
is my public album if you want to see what I'm up to. I'm still having a hard time inserting photos, sorry.

CafeDawg · « **Reply #94 on:** May 02, 2012, 07:53:21 PM »

rb550four

To insert a webpage you have to click on the hyper link icon above the smiley faces and the text box. Its the globe and when you do this should show up [url] [url] . highlight the web address then Copy and Paste it in between the [url]'s. For pics when your in photobucket put the cursor over the desired pic and when the menu drops down select image IMG code ie click on this and then go to your post and Paste pic their. Hope that helps. Damn you have some bikes!!! Maybe you could answer a quick question for me since you seem to breakdown a 550 engine a day. When removing the cylinder head cover is it necessary to remove the two shiny cases on the ends (not sure of the correct name and parts fiche doesn't seem much help)? they have an cross head screw in the center which on mine is buggered so if they need to come off any suggestions for removal.

this is the best photo I have.
If you can help thanks....sorry for the hijack
Respect
CD

rb550four · « **Reply #95 on:** May 03, 2012, 06:40:00 PM »

Thanks for the info on pics Cafedawg. I'll try it that way a little later.
And yes you will have to remove the cylinder head side covers ( the 2 shiny covers on the sides) as there is one bolt behind each of them that you will need to remove to get the cover off.
Honda has no more of these covers so don't break them , squirt the screws with PB blaster, lightly use and impact scewdriver if they are stuck. dont hit them hard, the head side cover plate behind the cover ( what the phillips screw threads into) will get sideways and tighter, if it gets like that , dont try to hit the screw with a punch thinking that they will back out, they won't,it'll just deform the covers or worse. I've found that drilling the screw head out will save the cover, the screw can be replaced, the cover can't. Good luck.

rb550four · « **Reply #96 on:** May 04, 2012, 06:22:37 PM »

I was planning to do this 72 CB 450 last year, this year it doesn't fit into my plans, never got title from PO, It is complete but, I may want to use the forks maybe... don't know. It ran 2 years ago and it's been taking up 550 space in the barn. I'm in upstate NY if there is anyone out there that woul

d be interested in it, will entertain offers.

rb550four · « **Reply #97 on:** May 05, 2012, 01:12:26 PM »

2 years ago I missed a 550 in decent shape , extended forks, king queenish seat, complete, kept under a tarp, no damage , and some surface rust.
This morning I drove 2 hours one way to buy sight unseen a 550, owner said it ran last year, may have surface rust but it's all good, and yes he has title ,the PO was a buddy of his and blah,blah,blah....
I get all the way out there to discover it was the one that got away, only it wasn't in as good a shape as the last time I saw it. It seems that the easy way to move motorcycles ,if you didn't know is with a Bobcat. Which looked like it was moved around the yard regularly, left with no cover, and generally F ed with all around in an attempt to Make it run.

Now, I am used to buying sh1tty bikes that I haven't seen before but, this one was a heartbreaker for me. Even if it wasn't all he said it was at the price he wanted, it was coming home with me.
It was on the road last in 87, been outdoors ever since. Both wheels were frozen when I went to push it into the truck, wouldn't move. Gave him his last jollies and let him Bobcat it onto the truck. Had to, I cut the chain and backed off the calipers-no move. PB'd it when it got home and got them to turn. I'm going out to take some pics of this little gem and should have them up tonight as I'm sure I'll be in the garage all day.

rb550four · « **Reply #98 on:** May 05, 2012, 05:18:09 PM »

Thanks again cafedawg ,OMG it so fin easy to move pictures! I don't know why I'm so thick sometimes, maybe it comes with age. I went back and popped some pics (that are in the album) on some older posts and I realized that I don't remember which 500 project is #1 or #2.
Maybe it's just residual carb cleaner fumes. Yeah, that's it , carb cleaner fumes.

CafeDawg · « **Reply #99 on:** May 05, 2012, 09:31:18 PM »

rb

glad it helped took me awhile to figure pics out at first. Thanks back at ya, drilled the screws outa the caps today and got the cylinder cover off, hope to get the rest of the head off tomorrow. Pretty sure I'm going to have to do pistons and rings and figure on putting a 650 cam in at that point. Somebodies been at this engine before but I don't think they got it apart just quit after the munged and snapped several screws and bolts. Those PO's don't always make it easy! But hey I only paid $75 for the whole bike so it doesn't owe me nothin. The seat on that 450 is pretty awful and gotta love those 70's browns and yellows. Good luck with the new acquisition. Just a little surface rust huh? Yup has a nice patina to it.

Respect
CD

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Author Topic: project 1 of12 started (Read 33645 times)