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Author Topic: '78 550K Resto-Mod  (Read 28820 times)

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Offline Scott S

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'78 550K Resto-Mod
« on: February 15, 2012, 12:49:44 PM »
 Back in June of 2011, I got a call from my Dad telling me that his buddy (who owns a cycle shop that generally deals with Harleys, cruisers, etc.) had just purchased a CB550, cheap.
 At the time, I was in the market for a 550 engine to swap into my CB500.
 I went to take a look at it and heard it run. After sitting overnight, it was smoking a little out of the #1 pipe. The guy who brought it in had played with the idle enough to mask the smoking.  8)
 It also needed tires, a little brake work. I offered the new owner double what he paid for it and rode it home. Oh, did I mention a clean title?
 Here's what $500 gets you. 
« Last Edit: January 29, 2013, 10:07:55 AM by Scott S »
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'81 Yamaha XS650

Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #1 on: February 15, 2012, 12:52:02 PM »
 Sold the rack and seat, did a little horse trading and picked up the correct headlight, front turn signals and ears. I also found this really nice stock seat. I think it's actually for a '77, but close enough for me. Did I mention it came with an owners manul and full tool kit? :)


 Looking better already!
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #2 on: February 15, 2012, 12:59:23 PM »
 Did lots of little miscellaneous things over the next few months. Cleaned the tank and rebuilt the petcock.



 Picked up an NOS Jardine exhaust.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #3 on: February 15, 2012, 01:02:43 PM »
 Ported and polished a head that I picked up off of ebay. BIG props to my Dad on this one.



 Match ported the manifolds.

 Clearanced for a CB650 cam.


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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #4 on: February 15, 2012, 01:13:05 PM »
 Picked up said CB650 cam and tach drive. I also found a CB750 tachometer that matches the 550K gauge faces almost perfectly.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #5 on: February 15, 2012, 01:34:38 PM »
 Picked up these 1.00 mm over pistons. I liked these because they use stock Honda style rings.
 This will give me about 563cc, which doesn't sound like much, but it's approx. a 3.5% increase in displacement which, along with the head work, cam and intake/exhaust changes should make a difference I can feel.
 (Sorry about the slightly blurry pics. Don't know what's up with my camera today)
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #6 on: February 15, 2012, 01:37:38 PM »
 Pulled the carbs and gave them an initial cleaning. I'll be going through them again to change the seats and try to get the jetting as close as possible. Anyone know anything about setting up the PD series carbs for performance?

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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #7 on: February 15, 2012, 01:38:59 PM »
 If you're gonna go, you need to WHOA! Dual discs anyone?



 I also have a GL100 master cylinder and I polished up a matching clutch lever.
« Last Edit: February 15, 2012, 01:47:38 PM by Scott S »
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #8 on: February 15, 2012, 01:40:29 PM »
 Disassembly started yesterday.


 And today, with the help of my killer girlfriend, I got the engine pulled and on the stand.


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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #9 on: February 15, 2012, 02:04:44 PM »
 The bike only has ~18,000 miles on it. I think I'm going to keep the bars (Euro bars) and stock pegs, even the big ol' factory lights (can't be too safe).


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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #10 on: February 15, 2012, 02:11:32 PM »
 Next up:
 -Clean the engine and get the jugs pulled and off to the machine shop, then a little apint/polish detailing.

 -The front end needs attention. The stock caliper is dragging and I've already picked up all the stuff I need for a DDC.

 -New fork seals, steering stem bearings and wheel bearing Fr. & Rr.

 - Mount the Bridgestone Spitfires. The chrome on the rims is NICE!

 -Dropping off the tank and side covers at the painter tonight!
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #11 on: February 16, 2012, 05:48:06 PM »
 Started on the front end today. Pulled the wheel and got the forks ready for new seals.


 I stripped the clear coat/anodizing off the forks (and about 7 years worth of inspection stickers) and prepped them for paint.
 Some genuis had used some sort of sealer or lock-tite or something on the allen head bolts on the bottom of the forks AND the old fork seals. It took WAY too much effort to get the old seals out. The RH one was especially bad.
 I was going to use 15W fork oil and add a few extra ounces, but the local shop only had 20W on hand so I just used the recommended amount.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #12 on: February 16, 2012, 05:51:34 PM »
 While I was picking up the fork oil, I had them mount the new Bridgestone Spitfire. I plan on polishing up the rim a little and cleaning up a couple of rusty spokes (I think there's a biker bar near here called "The Rusty Spoke"!).


 The front axle was also on WAY, WAY too tight. I bet we spent 20+ minutes before we could get the end cap on the axle loose.
 Next up: Start installing the dual disc stuff and take it back to be balanced with both discs installed.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #13 on: February 16, 2012, 05:52:21 PM »
 Took this opportunity to re-install the correct headlight ears and turn signals.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #14 on: February 16, 2012, 05:56:55 PM »
 I knew the front brake was dragging and I planned on rebuilding the caliper. However, when I moved the bike around the other day the front wheel would hardly turn.
 While the front end was apart I started removing the old brake stuff. Maybe it wasn't the caliper after all......
 Think this had anything to do with the front brake not working properly?


 The thing is, the master cylinder still moved fluid.....barely. I think maybe the return hole was/is plugged. I actually think I can save it with a good cleaning.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #15 on: February 16, 2012, 06:02:59 PM »
 Prepped the forks for paint and tried using some caliper paint I had, thinking that it might resist any spilled brake fluid, etc.
 Unfortunately, it started running before I had even finished the first thin coat! Maybe I didn't get all the stripper off the forks.....maybe it has something to do with the ceramic in the caliper paint....I dunno.
 I'll let it dry a while and then try sanding out the runs. If nothing else, get them smoth enough for a coat of Rustoleum.



 Up next, start installing the dual disc, have the wheel balanced and install the new master cylinder and braided lines. I'll get the tachometer while I'm there.
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Offline Greggo

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Re: '78 550K Resto-Mod
« Reply #16 on: February 16, 2012, 06:13:28 PM »
Very Nice Scott!!  Can't wait to see how it turns out.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #17 on: February 17, 2012, 12:56:33 PM »
 Well, I was able to sand out the runs on the forks and get a smooth coat of paint on them this moring. That's good, because I didn't relish the thought of stripping the paint!

 I also got the CB750 tachometer installed (to match the tach drive ratio of the CB650 cam).
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #18 on: February 17, 2012, 12:58:10 PM »
 Started the dual disc conversion. Got the discs bolted to the wheel....



 ...and dropped the wheel off to be balanced. The shop is also going to drill and tap a couple of small holes to mount the speedo drive adapter.

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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #19 on: February 17, 2012, 01:01:02 PM »
 Got the calipers apart and cleaned.  I FINALLY got lucky and had two calipers that would actually come apart with no frozen piston!


 And got them mocked up on the bike. I know I've got some fitting and shimming ahead of me. Just need to get the wheel back...

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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #20 on: February 17, 2012, 01:07:09 PM »
 My buddy just got a new dent puller/shrinker and was able to get the linear dent out ff the tank. Just needs a little metal work and no filler will be needed!

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Offline Bandit18

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Re: '78 550K Resto-Mod
« Reply #21 on: February 18, 2012, 08:19:20 AM »
Hey Scott,nice start on Resto I'm also working on the same bike and some of the same issues you have.What is the best way to strip that clearcoat off the forks.Keep up the good work I'll be keeping my eye on this one.I'm from right down the road by the way, it seems there are a lot of us Carolina boys on here.
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Offline sniper1

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Re: '78 550K Resto-Mod
« Reply #22 on: February 18, 2012, 10:21:43 AM »
I just did mine and used paint stripper in an aerosol can from Wal-Mart (in the paint section). Spray it on, leave it for about 15-20 minutes, scrub off with brush and water, Good to go.
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Offline Scott S

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Re: '78 550K Resto-Mod
« Reply #23 on: February 18, 2012, 12:36:34 PM »
 Yep, Sniper1 has it correct. You can also try oven cleaner to remove clear coat/anodizing. You'll still need to hit it with some heavy ScotchBrite pads or sandpaper if you want to smooth them out a little bit. That's mostly if you're going to polish them, though. I didn't get too crazy on these since I was going to be painting them.

 Bmoffit18, are you on Facebook? Check out the "Friends of the Queen City Aces" page.
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Offline Bandit18

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Re: '78 550K Resto-Mod
« Reply #24 on: February 18, 2012, 06:25:03 PM »
I'll will definitely check out the site on FB Scott.BTW who drilled your rotors,They look sweet and there going to look great on your bike.
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