Topic: CB550 Cafe, back from hibernation. hopefully.

[ocharlas]

Hey guys, new member here from NY.  This will be my first time trying to really build a bike.  I've done some minor stuff like fork seals but nothing really involved.  I picked up a 1976 cb550 on CL for $300 bucks, pretty rough looking but 90% complete.  Seller also threw in a parts bike, no tank seat or electronics but wheels, suspension, and engine are there.  I started posting over at motorcycle forums.com but I like that this is a dedicated Honda forum so I'm moving in if nobody minds.

The engine does turn over, but the bike looks like it hasn't run in a long time.  Electricals are shot, all of the hoses are disconnected, there's no chain, tires are rotten.  There's also no key and no battery so I couldn't even try starting it.  So after looking at it and scratching my head for a while I decided to start taking pieces of willy nilly.  As of now I have the seat, tank, exhaust, rear wheel, handlebars and rear fender/taillight all off, which leaves the whole front, engine, and rear suspension on.  Now I'm not what you would call a meticulous person by any means, but I would like to try and see this through AND make it nice.   Standard cafe fare: club bars, 4/1 exhaust, cafe seat, maybe different gauges.  I'd like to do some performance upgrades down the line, but for now the goal is going to be making it shiny and working.  I am going to chuck all the wiring andre run everything,but try and keep it pretty stripped down and basic.

I guess the first order of business will to clean up and paint the frame, so I assume everything has to come off first.  Is there anything I need to know before I just go for it or can I keep just taking stuff off? 

In any case I'm pretty excited to work on this and hopefully I can see it through.  I look forward to hearing from everyone here, there seems to be a lot of knowledge flying around.

Thanks

[rb550four]

Welcome fellow New Yorker. Nice buy for $300. Yeah taking it down to the frame is a real good place to start. You can inspect each part as you remove it, you can clean, paint or buff those parts as you go so they are in prime shape for reassembly. If you don't have a shop manual, you should get one. This is the  site if you need to know anything about a SOHC,  lots of 550 owners , and  there is much wisdom here and folks like to share it. Keep us updated, and there is no such thing as a stupid question..,well okay there is, but everyone is interested in projects and willing to give you an idea if you get in a jam.

[LesterPiglet]

Take plenty of pictures for reference. Welcome to the forum.

[ocharlas]

Thanks guys.  I've been literally drooling over the bikes you guys make, absolutely gorgeous machines.  if mine comes out a tenth as good I will be a happy man.

First question:  how the !@#$ do you guys get your parts so shiny and beautiful???  I've read a couple different methods on this site but  I'm mostly wondering about trickier things like the engine, wheels/ spokes, etc...I shined up the fenders a bit using steel wool and wd40, but the effect is not quite the same - plus some of those areas look difficult to get into

[LesterPiglet]

Don't use steel wool on chrome. If the chrome is spotted with rust try aluminium foil and coke...as in cola. The acid in the coke neutralises the rust and the foil is softer than the chrome so it will not damage it. The foil will also leave a silver film on the rust spots making it look that bit better. Toothbrushes and anything similar for hard to reach areas.
For spokes I cut lots of strips of cloth and use a chrome cleaner. Loop the cloth around the spoke and pull back and forth.

[ocharlas]

Awesome, thanks for the tip.  I'll give it a shot tomorrow.  do you soak the parts in coke for a while or just use it as a cleaning agent and pour it over the chrome while you rub it down with the foil?

[LesterPiglet]

Pour it on as you need.

[messeduptriple]

Take plenty of pictures for reference. Welcome to the forum.

much agreed!!

Sent from my PC36100 using Tapatalk

[dagersh]

Welcome New Yorker!  Where you at?

That is a great score for $300, and in reality, its no where near as bad as you think!

If I may make a suggestion, start working towards a rider - make sure the bike will run, is safe and reliable.  Then concentrate on the cosmetics.  This I have learned from experience.  If you are going to make any cuts on the frame (i.e. bracket removal and the like) you want to do it before you paint!  There are many changes I would have done before Powdercoating my frame that I can't do now without incurring a huge expense.

Also, if you know the bike is a good runner, you know it will be worth the time and cash to customize as you see fit.

Anyway - clean what you want to start.  Look at sites like Caswell Plating, Eastwood and Youtube for polishing tutorials.  I have a buffer set up, but I won't tell you I have not had great results using just a power drill ith a hardware store buffing wheel and compound.

Anyway - these Hondas are incredible - the engines can be brought back from much worse shape than yours.

Keep us updated with copious amounts of pictures and ask any questions you want!

Gersh

[ocharlas]

I'm up in Dutchess County, Millerton to be exact.  Not quite hours north of NYC. 

I definitely plan on focusing on the mechanicals over the cosmetics.  That being said...there's a couple things I'm just gonna have to do.  But like I said, a big part of this build is going to be me learning how to do different things.  Hopefully I can try my hand at a little of everything: mechanical, electrical, bodywork, paint, etc...I'd like it if this wasn't the last motorcycle I restore. 

Originally, I wanted to make sure the bike could run before I really got down and dirty.  But after seeing that that wouldn't be possible (at least not for me), I decided to completely flip my game plan.  So now the idea is to (try) and treat this build like I know what the hell I'm doing.  Tomorrow, come hell or high water, I'm taking the engine out, the rest of the wiring, suspension...everything really, down to the frame.  Then I'll check it out and make sure it's not rusty, grind down the rust spots and things I don't need, and start slapping paint on it.  You know, like you guys do. 

I'll make sure to take pictures and keep everyone posted.

[ocharlas]

weelllll...that did not go as planned.  I tried taking the engine out of the bike this morning using a technique I saw on this forum, a jack stand on each side, 2x4 going across and two tie-downs.  Well, after battling around with it for a while I realized one thing:  this ain't happening.


All the mounting bolts/plates/etc are out, and the engine moves around pretty easily, so then my next great idea was to tilt the bike onto a carpeted dolly engine first, and simply lift the frame off of the engine.  So easy!

Nope.  I wound up still not being able to get the frame off of the engine.  I took off the oil pan, and whatever that thing is in front of the oil pan (which also has oil in it) and it still won't come off. 

After coming back here and looking at other threads though I smacked myself in the forehead: carbs are still on.  I'll try to right the bike and take them off tonight. 

No pictures either...it's a shameful sight right now.

[LesterPiglet]

That thing at the front with oil in it.   

[ocharlas]

Yeah yeah, pick on the new guy. 

 how was I supposed to know it was the filter housing with no filter in it!

[LesterPiglet]

I hope you have downloaded the manual, if not here's the link.

http://forums.sohc4.net/index.php?topic=426.0

[wedoo2]

As they say, no pictures, it didn't happen.

Keep asking questions, there is a lot of information here and a lot of guys to help and most of it is literate.  To get the motor out loosen the motor mount bolts and nuts, lay the bike on its side and slide the frame out over the engine.  Oh yeah,  take off the carbs and air filter stuff.  Also, gas will leak out of the tank if you don't take it off first. 

[jaguar]

Welcome fellow NYer
I have to ask about the logic here though....If you cant get it running then why take it apart?
Often that will only add variables down the line and make things much more difficult.

Sit and take things slow with the manual.
Any old bike will give you plenty of things to learn and mend without trying to make things harder.

[rb550four]

I never tilt the frame to get the motor in or out. I leave it on the centerstand if there is one. Remove tank ,shifter, the cover behind that,the chain , and carbs,leave the manifolds on,remove wires and cables,oil pan and pickup,pipes,valve cover and that thing in the front with oil in it. mounting bolts out. I put a milk crate with a 2x12"  on the points cover side,and a strip of cardboard on the frame. Get on the bike and lift the intake manifolds  with right hand and exhaust studs with the left, pick up engine slip right side bottom of engine onto 2x12 bring left hand over frame,grab another exhaust stud and put the engine to rest on the 2x12. haven't had any problems with  this way yet. but that's what I do. It goes back in the same way except I add a floor jack  in the center of the cradle (from the left side)to get the engine to the desired heights for reinserting  the mounting  hardware , as an added bonus, fingers don't get pinched. Like I said ,that's how I do it. You can also use a floor jack during removal to get the engine up high in the cradle. My floor jack has a rubberhead, if yours doesnt, put something softer ,like a 2x6 between it and your motor.  Note seat removal option: easier if it's off.

[ocharlas]

2:30am update:  the engine and the frame are in two different places. 

My brother and I just spend right around 2 1/2 trying to get this thing out.  We started with the jack stand/2x4/straps method, moved on to the lifting it out of the frame method (then back to the straps), but in the end we did have to pull a tilt.  We took the carbs off and disconnected a bunch of other stuff, but I'm sure there could have been more removed to facilitate the experience.  Tomorrow I'm going to start cleaning up the frame, probably just with a drill and wire wheel.  Since I don't really know what I'm planning to do to the bike as far as color I'll probably just go for back.  Also I love a nice matte finish but I'm not sure how well that'll hold up.  How do you guys feel about rustoleum?

I can finally post pictures - albeit really crappy ones.  The light ain't great in there

[ocharlas]

Finally - down to the lawn sculpture element.



It's not really that bad.  Some surface rust obviously, but nothing deep (at first gland at least).  It is pretty greasy and grimey though.  My current plan of action, with help from the tech tips section:

Clean:
WD-40
Steel Wool

De-rust:
Wire wheel/drill

Hose Down

Paint:
Gloss Rustoleum Enamel

Am I missing anything?  Should I throw a clear coat over the enamel, or a primer under it?  Also, is it necessary to completely strip the frame, or just get the problem areas and then sand it smooth? 

[LesterPiglet]

If Rustoleum is the same as Hammerite/Smoothrite it doen't need an undercoat.

[ocharlas]

Also just thought I'd mention that I'm not going to be reusing alot of stock parts if anyone is interested in them.  If I remember I'll throw them up in the classifieds sections, but basically I have (I believe this is a 550K)

stock exhaust, 3 pipes in good shape, 1 has a hole in the bottom.  Otherwise should clean up nice

rear fender/taillight - a couple small dings, but overall good shape.  Very light surface rust.

stock front signals - in good shape. 

stock rear signals/rack - in good shape

stock handlebars - look decent

stock gas tank - will need repaint but looks to be in great shape.  Not looking to sell this outright but would like to trade for a more cafe style tank

That's all I can think of for now.  If anyone's interested in any of these shoot me an offer.

Mods if this is a problem feel free to delete this post.

[LesterPiglet]

If your fork ears are in good condition I will trade for a set of 4 new small indicators...unused. PM me if interested.

[kerryb]

I'll take the exhaust, how much do you want and where are they?

[ocharlas]

Honestly, I wouldn't know what to ask for so if you want to make an offer that would probably make more sense.  I'm putting up a few pictures so you can see what they look like.  I didn't clean these up at all so they are pretty rough, but they should brighten up.  As you can see the third pipe is damaged.   Oh, and I'm located in Millerton, NY.  It's quite a long way south of you.





Also, even better than money is if you have parts to trade - I want to replace these pipes with a 4 into 1 so if you have something in good shape to swap I could get down with that.  Let me know.


PARTS UPDATE - I also have:

set of stock gauges in good condition.  Like everything else I assume they work, but nothing on the bike has been tested.  The chrome looks nice, but the black casings have some light corrosion on top. 

stock seat - not great condition.  The frame looks ok but the cushion is shot. 

left and right controls - just the casings, in nice condition.  Wires are cut. 

Money is good, parts are better!  For every part I get rid of I'm going to need it's cafe style replacement so if you got something let me know.

Now back to the build!

I'm stripping down the frame and getting ready to paint it, hopefully tomorrow.  Ideally I would like to cut off whatever mounts I won't be using: side panels, rear footpegs, horn, helmet holder...I'm not sure what else I can get away with but I'm open to suggestions.  Also, is the  one circled in blue one of the battery mounts (can't remember where the other is)?  I love when I see bikes with the battery under the seat, but am not sure I have the chops to pull it off.  Thoughts?

Lastly - if I grind these off, is there going to be a big hole left that I have to weld?  Or are the mounts welded onto solid frame?

Here's a picture of the ones I'm thinking about getting rid of.  Feel free to sound the alarm if I'm about to do something stupid.

[jaguar]

lot of people use the passenger pegs to mount rearsets