Author Topic: project 1 of12 started (Read 33752 times)

rb550four · « **Reply #50 on:** February 28, 2012, 07:38:25 PM »

So this cafe style 72 500 that followed me home has been more than tinkered with,while looking through the neatly bagged engine parts, I'm seeing non factory pistons,look bigger than usual ,ha , 550 size that's a treat. Crankcase has been cleaned and closely examined,looks good and back together it goes. This one could have waited but it takes up 3x the space in boxes, and we all know that it doesn't matter how big we make our garages....we find a way to fill them.

rb550four · « **Reply #51 on:** February 29, 2012, 06:49:06 PM »

The bottom end went together nicely so I thought that it was time to work on the middle. Honda rings fit real good on those pistons, the non factory wrist pins were snug, real snug, hope not too snug. The jug was a 500 that has been bored to the 550 , cylinder walls look really thin, my faith in this build is diminishing, I like true and tested factory specs. These hot rod engines don't make sense to me, if you want a faster bike get a faster bike, any increase in performance on this build would be marginal at best so why sacrifice dependability? So this is the 2nd machine that came home with an oil cooler, don't know what to think about those, same factory oil pump, more line to be pushed through and all up hill because of exhaust pipes. Should I leave this cooler on being that the cylinder walls have been bored so thin? Maybe I should just #$%* can the whole middle and go used factory spec parts. But I can't help but wonder , what if I'm wrong and this could be the fastest thing in the yard, is it worth taking the chance? $:-\$ could use some feedback.

rb550four · « **Reply #52 on:** March 02, 2012, 07:21:25 PM »

So I decided to go forward on this motor, with doubt,and find a comfortable place to bail if need be. Took out the wrist pins out and buffed them down a little just so they weren't too tight and installed the pistons and rings,could have bailed but didn't. Slipped the jugs on, lapped the valves, found one spring in 3 pieces,but I have the extra parts so I switched them out,that could have been a place to bail but I didn't. Carefully applied "O"rings and head gasket ,torqued down the head,slip in the cam chain tentioner (from the box of parts) won't go it's bent,straighten it , slips past the seat , tip the motor sideways and feed it into the seat from the bottom,not quite right. Something is blocking my view, it's the primary chain that I thought didn't look like it was hanging low but the side to side slack was out of control and very unacceptable .Then I stopped and questioned if it's worth a new primary and tear down? There's 2 more 500 motors on the bench and I'm thinking now might be the time to bail and just build a stock motor for this cafe , salvage the head,gears,and clutch and move forward....I guess. Or I could just go with a 550 jug that' taking up shelf room,get a new primary, and problem solved give or take 10 hours. Sometimes mechanical activities can become run of the mill, this hasn't been the problem here lately.

rb550four · « **Reply #53 on:** March 03, 2012, 04:18:23 PM »

Ordered new primary chain today. Degreased the frame and broke it down for a light sand and paint. The wiring harness was as expected, I don't know why when it stops running , people start cutting wires. And I was unaware of the metric hardware shortage of 12 years ago, there's allot of SAE nuts and bolts on this thing. I'm not complaining, I just find it interesting. Right down to the lack of lockwasher usage, I found 4 on the whole bike and they were wedged inside the front motor mounts under the nuts that fit in the bottom cases

there were none on the front axle. It's a sneaky weight saving trick for sure.

rb550four · « **Reply #54 on:** March 05, 2012, 06:38:19 PM »

The weekend came and the 500 motor is on the bench waiting to get torn down again, the parts should be in Thursday so I put a motor in my favorite 500, rebuilt 2 racks of carbs and put a set in. I can repaint it next year, right now all I want to do is ride it, but first I'll have to dial in the spark, I have a few tune up kits and some dyna S electronic ignition kits on the shelf, haven't tried the electronic stuff yet. Is it really that much better than points? I almost remember reading that it requires a hot wire, should I tie it into the fuse box or splice into a wire in a handier location? The PO of the cafe 500 that followed me home spliced into the black and white wires on the coils, don't know if that's a good spot , PO said it ran rough, but there were many obvious reasons for this and it may not have had anything to do with the dyna s setup.

rb550four · « **Reply #55 on:** March 14, 2012, 08:11:37 PM »

Parts 7 days late. Painted the cafe frame and reshot the project#3 frame in gloss black, started reassembly on the cafe. It's a roller now with a repaired wiring harness. Went to Pittsburgh for 3 days, no bikes followed me home for a change. Checked on parts, be here tomorrow, we'll see.

lucky · « **Reply #56 on:** March 15, 2012, 12:44:47 PM »

Quote from: rb550four on February 22, 2012, 07:12:31 PM

This is project 500 #2,rebuilt engine last week

Is this the BEFORE photo?

Click once on the photo to enlarge image.

lucky · « **Reply #57 on:** March 15, 2012, 12:55:44 PM »

Quote from: rb550four on March 05, 2012, 06:38:19 PM

The weekend came and the 500 motor is on the bench waiting to get torn down again, the parts should be in Thursday so I put a motor in my favorite 500, rebuilt 2 racks of carbs and put a set in. I can repaint it next year, right now all I want to do is ride it, but first I'll have to dial in the spark, I have a few tune up kits and some dyna S electronic ignition kits on the shelf, haven't tried the electronic stuff yet. Is it really that much better than points? I almost remember reading that it requires a hot wire, should I tie it into the fuse box or splice into a wire in a handier location? The PO of the cafe 500 that followed me home spliced into the black and white wires on the coils, don't know if that's a good spot , PO said it ran rough, but there were many obvious reasons for this and it may not have had anything to do with the dyna s setup.

The electronic ignition comes with instructions and a wiring diagram.

rb550four · « **Reply #58 on:** March 19, 2012, 04:06:01 PM »

That is a picture of project #2 before rebuild Lucky, and that was pretty funny by the way. And I will look a little harder for the Dyna S instructions. #2 is coming along,right now it looks like

rb550four · « **Reply #59 on:** March 19, 2012, 04:10:59 PM »

#1 is coming along, it looks allot like one of my 550's.

rb550four · « **Reply #60 on:** March 19, 2012, 04:21:28 PM »

There was this little 500 cafe with a beat everything, it looked like this when it came home. The engine parts finally came in on Friday. It was broken down on Saturday afternoon, rebuilt and loaded in the frame 2am Sunday morning. Wiring harness repaired that afternoon and looking better( pics when finished). It came with cheap ass fiberglass front fender and the exact windscreen that Killer Canary has on his bike (okay, if it isn't exact, it's close) plus 1 extra plexi ,not sure if I'll use it yet.

rb550four · « **Reply #61 on:** March 19, 2012, 04:24:27 PM »

Only a couple more 500 motors left to do, Then it's 550 time.

rb550four · « **Reply #62 on:** March 19, 2012, 04:31:34 PM »

So a few months ago this 550K followed me home complete with fairing, hard boxes, 2 sissy bars, a touring seat, and a rear hardbox. This stuff isn't for me, someone might like it on Ebay or something, I guess.

rb550four · « **Reply #63 on:** March 19, 2012, 04:38:36 PM »

This one is so complete that it is a candidate for a stock restoration, I kinda like it without all that jazz.

rb550four · « **Reply #64 on:** March 19, 2012, 04:43:20 PM »

I compacted the machines and made some workspace in the garage, and, I may be able to get another 2 or 3 in there.

Tews19 · « **Reply #65 on:** March 19, 2012, 07:29:23 PM »

RB, on the fairing pic, the cool fairing, I cant make the pic bigger. Or the pics that follow. Man how big is your garage? Keep the pics coming

rb550four · « **Reply #66 on:** March 20, 2012, 06:53:31 PM »

Yeah, I must have done something different when I posted these photos, next time I'll try to get it right. The garage is 28 x 32 or I'm guessin 20 Hondas with extra room for a few spare 7.3 diesel truck parts and tools. It really isn't big,it's just the pictures are small.

rb550four · « **Reply #67 on:** March 20, 2012, 07:16:31 PM »

So last fall I went to a flee market and picked up a box of nos early 70's blinkers for 3 bucks each. Of course Id like go through and change out some of my pitted /scratched ones later on, but on this cafe build I wanted something a little smaller that maybe was a little flexible and in the corner of the garage there is this Suzuki gz250 in a heap next to the 72 dohc 450, and the blinkers are just what I wanted ( already put the tank on project#2). They tuck in a little closer to the frame, are rubber mounted, and bolt up nicely to the SL 350 type headlight brackets. Just a little drilling on the rear fender holes on the back of the frame and they are in. As an added bonus , the Suzuki taillight with some alteration, fits and looks correct under the cafe style seat. I'll wire it up and take some pics, I'm really pleased with them so far and thought this information should be shared. Anybody need a gz 250 engine with only 850 miles on it (Started it last fall)? Swingarm, wiring harness and rear wheel are good too. It almost was installed in my lawn tractor last year, this year I don't have the interest.

rb550four · « **Reply #68 on:** March 23, 2012, 08:33:49 PM »

The 500 cafe fired up. It had some cheesy aftermarket coils that I put back on but they had to be switched out with stock ones that actually work. Ordered petcock gaskets, major leakage problem,I'll put a different tank on tomorrow while waiting for gaskets , still have to dial in the spark and sync the carbs and maybe clean that little fairing up some and try it on. I can't decide if it looks cool or not. pics to be posted tomorrow.
Okay, it's tomorrow, switched out the tank,dialed in the spark,syn'd the carbs. Took it for the plateless first ride. My this little bugger is pretty quick. Tires have some age and the rim condition could be better so, There is a drowned 550 in the lineup with new rubber and aluminum Italian rims, I'll switch them out in the morning

rb550four · « **Reply #69 on:** March 25, 2012, 05:56:47 PM »

Sorry, took pics, having a size problem . Computers are harder for me to deal with than carbs. But I did manage to get the pic with that Suzuki tail-light and blinkers. I like the way the taillight tucked a little under the seat with a curve that seams to compliment the pan's shape ( the vinyl is crap of course),and the smaller clean cut rubber mounted blinkers seem to just belong there (instead of on a Suzuki).

rb550four · « **Reply #70 on:** April 03, 2012, 04:22:51 PM »

This maybe ?

rb550four · « **Reply #71 on:** April 03, 2012, 04:26:48 PM »

maybe this? Like I say, not sure which one looks the best, it's fun but I don't need to make a twin, do I leave it on or take it off?

rb550four · « **Reply #72 on:** April 08, 2012, 03:37:03 PM »

I was thinking that those 2 500 engines on the bench could wait and I'd start on the 550s, but my bench is only big enough to work on 2 at a time soo, since there's already 2 on it and I have most of the parts, might as well get crackin on those and get them out of the way. Both were locked up , so the cam chains got cut off and the head removed. Much two my surprise the first motor had 2 and 3 tdc and a full load of schmutz on the tops of them,#4 had an inch of schmutz in the cylinder. Moving onto the final 500 motor , exactly the same way ,right down to piston positions.
Both heads have a couple( at least) frozen valves. One head has a busted spark plug (threading only) stuck in it. This could turn out to be a long day if I didn't leave it alone .So penetrating oil was added and both motors are being hung for a day. day two changes up to a penetrating oil and tranny fluid mix. today I took the fluids out and put in straight seafoam ( this sht is good for everything) And it's still hanging.Maybe it needed to be nudged loose a little so in a desperate move I cut a slug just smaller than the piston diameter dropped in a 1 1/4 socket upside down and gave it a couple shots on each piston while still hanging with an air chisel, not long, just enough to jolt out some rust from the rings,cleaned it out and resoaked with seafoam. They are both still hanging.

Tews19 · « **Reply #73 on:** April 08, 2012, 06:43:24 PM »

RB, may I ask how old you are? You have so many bikes you are working on, I wonder where you get the time to work! Very envious of yout time management skills!

On a side not, seeing you have lots of 500/550's would you happen to have a keyed ignition w/ key you may be willing to part with for a decent price?

rb550four · « **Reply #74 on:** April 09, 2012, 02:14:39 PM »

Tews19 , The body is all of 53, the mind seems much younger, and for some reason 1977 still seems like just a few years ago. Don't know if it's like that for everyone. I ,like all of us ,started out with a 500 that needed parts. Bought a 550 cheap, turned out it was too nice for parts, fixed that one (almost stock burnt orange one) and bought another for parts, same story,rebuilt it (the gold semi chopped w green frame). This was getting to be a problem since I always needed parts, so maybe I should pick up the crappiest ones I could find because they are cheaper in poor condition and I couldn't rebuild them (not true), finally just parts right? Kind of ,the red framed parts bike turned out to be in good enough condition after all the parts changing to end up being the orange 550. Along the way sellers need to get rid of some Kawis and threw them in the mix, thus the green kaw/550, a few partsbikes later the other green 550 is built. I had some parts 2 Octobers ago and realized there would be no riding till spring. Doesn't have to be that way, grafted a derelict snowmobile to a 550 frame (snowbike 550). Total build was two months. and on and on.... It seems that the hunt is as much fun as the build ( I rebuilt all the motors when I had time and slip them into the next candidate) so there is always a project, I check 4 states each night so there is always a candidate. I've been rebuilding old houses for the last 25years, since the kids grew up, I only work 8 hours a day , and I need to be busy til I get tired or I drive my wife nuts....This thing with the bikes... well before that it was with 350 ford duallies,too many for the driveway,all rebuilt and licensed, take a different one out everyday, drove the Mrs. crazy. Bikes are smaller,stay in the garage so she can park in the drive....it's better. She don't care how long I spend in the garage, there are so many worse things that I could be doing.That's my story. As for keyed Factory ignitions, I'm in the same boat as everyone else, Emglo. Thanks for the interest. By the way, your 550 build is coming along very nicely.

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Author Topic: project 1 of12 started (Read 33752 times)