Topic: 1977 CB550 project, seeking advice...

[vincentlefre]

Hi all,

I'm about to begin a compete strip and rebuild of my '77 CB550. It will be mildly customised aesthetically and mechanically to improve all aspects of the bike.

I have been trawling the forums for months now picking up useful information but was hoping to try and get some answers to a few questions based on tried and tested methods in terms of generally improving the way this bike performs. I might add that she already runs electronic ignition timing, I have a cb650 camshaft ready to go based on that proven mod, I will be porting the head and replacing all engine parts that are worn, making an entirely new wiring loom and fitting tapered headstock roller bearings. The aim of this bike is to look good, carry two often and perform well on a daily basis. Budget for the build is flexible within reason, I'm not looking for titanium racing valves or anything like that.

The questions I have are as follows, any help or real-world advice on any area would be hugely appreciated. (please bear in mind I'm based in the UK so some suppliers may not be usable)

What other reasonable engine upgrades would you recommend? i.e. valves, springs, chains, sprockets
Clutch plates will be replaced, can anyone suggest my best option for performace and reliability?
What electrical components would you replace and with what? i.e. regulator/rectifier, coils etc
Does anyone know of an alternative battery that will perform better than stock, preferably sealed?
Was considering Hagon rear shocks, can anyone reccommend a specific variation or another make altogether?
Will be rebuilding front forks, any advice on uprating the internals?

Finally any other solid upgrades on a '77 CB550 to make it an even better bike?

If I think of anything else I'll post 'em up.

Thanks in advance.

[luap]

Ive used the ecb clutch plates an springs 1500 miles on them with out any problems, saw a good post about drilling the clutch basket an replacing some o-rings -to cool the plates an be ablle to getinto nuetral easier, also been reading motorcycle oil will help coat better then castrol
dyna coil 5 ohm( black ones) 7mm wire I like the ngk caps nd7ea plugs, siriusconinc carrys 7 line sinlge state regulator rectifier dyna tech electronic ignition( in my buddys bike for 1000 miles)
Havnt had any problems with my bike master sealed  battery , running a new ballistic battery in my new bike but havnt riden it enough to see if its worth a damn
the progressive front fork springs have been good for me
in the build threads theres a guy Irish something hes got a real nice rear swingarm set up an pretty sure he is running the same shocks you mentioned(900.00 set up)

[Bankerdanny]

Personally I wouldn't replace the wiring unless there is something wrong with it. I think the Hondaman bladed fuse block upgrade is worth while. I would swap out the tail light and turn signals to LED. I would install a relay on the headlight circuit to support an upgrade to a halogen headlamp.

I am a big fan of the sealed AGM batteries, which are available from most of the battery companies. They cost a bit more than conventional, but my experience was that they really complement an electronic ignition.

All that said, I kept my '77 550 bone stock, it was super clean and all original when I got it. I put in a new ordinary battery, new gaskets in the carb, new tires and fork seals. The rest of the bike was as it came in '77 including the  original points and plug wires, chain, and brake pads and lines. It ran like a champ, got 45-50mpg, easily cruised at 70-75 on the highway with my 225 pounds on it and took me on a trouble free trip around Lake Michigan last summer.

[vincentlefre]

Thanks for the response, those are some good tips.

Re: the wiring - although electronically most of my components are working, the loom is tired and whoever fitted the electronic ignition did it in a hurry. I'm also gonna be cutting out a lot of components like the clutch switch, emergency stop switch etc so a spanking new, custom made loom is in order. I'm experienced at this so it won't be a problem. Just want to make sure I get the best components in the circuit for reliability etc.

Would be good to get a link to the post about drilling the clutch plates, haven't heard about this mod.

Also what kind of relay is necessary for a halogen setup? I'd love some more information on doing this conversion properly. I have a smaller 5 3/4" headlight that I'm going to fit but would love to convert to halogen especially as the whole headlight will be stripped anyway. Would something like this be suitable to fit into what I already have? - http://www.ebay.co.uk/itm/5-3-4-12V-MOTORCYCLE-HALOGEN-HEADLIGHT-HEADLAMP-CRYSTAL-CLEAR-H4-BULB-60-55W-/370546774111?pt=Vintage_Car_Truck_Parts_Accessories&hash=item56464f105f

[Bankerdanny]

There are about a dozen videos on YouTube on how to install the headlight relays. It's really a pretty simple job and the parts are readily available at your typical chain auto parts store for about $20.

I upgraded my Enfield from sealed beam to an H4 removable bulb halogen and the difference was amazing. The light was so much stronger that it was like my bike didn't even have a light before. From a safety perspective its at the top of my list of mod's to upgrade an older bike.

[luap]

http://forums.sohc4.net/index.php?topic=78643.0
link for drilling the clutch basket
http://forums.sohc4.net/index.php?action=dlattach;topic=85767.0;attach=172772;image
swingarm set up

[Rgconner]

Take a look at this bulb:

http://shop.conrad-uk.com/car/maintenance-service/car-consumables/car-halogen-light/856419.html

55/65w can strain the stock alternator if everything is not just so.

[Accolay]

There are some tidbits in the FAQs under "The Thoughts of Hondaman" if you're interested.

[Danno]

the smallest AGM will not fit in the battery box of the 550 without modification but works well and the led lamps can be used on one end and not both with an electronic flasher installed
 it can only be installed both ends if you remove the reminder beeper from the circuit
 
the heavier clutch springs and heavier valve springs are worth while if you are going to put a cb650 cam in it or other aftermarket longer duration cam (not higher lift) porting and polishing will give you your greatest improvement if done right

[vincentlefre]

This is all great advice, thanks, keep em comin'

[vincentlefre]

Take a look at this bulb:

http://shop.conrad-uk.com/car/maintenance-service/car-consumables/car-halogen-light/856419.html

55/65w can strain the stock alternator if everything is not just so.

What kind of setup would I need to run this bulb? Do I need a relay of some kind? Is this the buld you use?

[Bankerdanny]

It is possible that your stock setup would run the bulb fine. However there is a real risk that your connector at the lamp or the high/low switch would burn out or melt from the heat that the extra draw caused. The benefit of the relay is that it carries the draw from the bulb and the switch does not. I think it is also worth while to upgrade the connector to a new one from the parts store that is made for modern cars with more powerful halogen bulbs.

[72500john]

got a stock bulb for my 72 500 from honda..amazingly cheap 12 bucks and put hondamans relay kit in 28 bucks..shall we say the difference between night and day! agree a must mod for these bikes.