Topic: '77 CB550K - First bike ever. "Dirty Gold"

[jinx2350]

So I've had this bike since November 2011.  I've done a fair amount of work already, so some of this will be catch up.  I'll fill this in slowly and catch up to the present.

The story goes like this: Found in on craigslist down in Drain, OR.  Yes, that's a real place, outside Roseburg.  It would Barely start, but in fact started.  The carbs were pissing gas all over the place, and it wouldn't stay running.  Tank had a few dents, cracking dull, gas stained original paint...but man I love that patina on the old graphics and badges.  This is what inspired the name "Dirty Gold".

Turning over, and spark was good enough for me though. $900, loaded it in a trailer and brought it home. 

Here it is on day one in it's new driveway.


Got it home, and started assessing what was what.  With my very limited knowledge I realized it needed short list of things right off the bat.

• Exhaust, farthest right pipe was cracked at the muffler and aluminum taped back on
• Seat. Wasn't original anyway, and badly sun bleached/dry rotted.
• Carb clean or rebuild
• Remove superfluous ugly bits..mirrors, turn signals, etc.
• Tires. terrible dry rot
• Get headlight working

Photo of the cracked exhaust



Just for grins I got new plugs, Uni filter to go in stock box, new battery, and an oil filter.

So I went a little nuts with it, and got it to here and realized I needed some professional help with carb work, stuck brake caliper, and exhaust installation.


I did lots of internet cruising and debated getting the MAC 4-1 black headers/exhaust.  Then I found the stainless steel exhaust that Lossa sold, and he had one left so I jumped on it.   I'm still confused as to the origin of these pipes, I've also yet to ask Lossa either.  some say  Chris @ MotoGPWerks, Carpy, whatever. Lossa was selling, I was impulse buying.  In retrospect I'm in love with the pipes look and sound.  I do believe I could have gotten them for less than $500 + shipping.  Live and Learn.

After making all these rash decisions, I was on craigslist hunting CB parts and found Doomtown Motorworks here in Portland.  Run by forum member Paulages. He was super helpful in scrapping my thoughts of pod filters, and encouraged retaining the stock box.  Loaded the bike on a trailer (and in a few boxes), and dropped it off the have the exhaust installed, carbs ultrasonically cleaned, brake caliper un-stuck, and just a general tune-up (carb sync, etc.)  Paul did the work, and limped it home.  Ran great in the shop, and then crapped out twice on my ride 2 miles home.  Lesson learned on always checking the petcock. Rookie move, that won't (probably will) happen again.

Here's what it looked like when I got it home.


That's all I've got for now.  I'll put together my wish list of upgrades on this project in the next post, as well as document the 2 parts bikes I grabbed, along with 3 boxes of new/used parts. 

[goldarrow]

Welcome to the forum.  plenty of helps here and you'll be in good hands.  i never took a bike apart and now i'm down to pistons work. 

and yes, photobucket account is great. 

good luck with your build

[jinx2350]

I really do love the flaky decals on this tank, but hate the burgundy/brown/rootbeer color. Eventual plans are to strip the tank to bare metal and leave that way, but put on replacement decals in the red/black/gold. Also, retain the actual "Dirty Gold" badges as they are and use them as well.   I REALLY wish I could remove the stock decals that are on there now, and re-use them on the bare metal tank.  I seriously doubt this is an option or even in the realm of reality, but a man can dream.

[luceja]

I think I was at doomtown when your exhaust was getting installed. Mean looking pipes!

[jinx2350]

Mean sounding too!  I have this idea running around in my head to attach on of these one day.


Not sure where exactly, but I like the idea of some bronze exhaust wrap, and black ceramic coating this thing. Maybe even right after the headers, underneath the bike.

[LesterPiglet]

Looks like 9mm shell casing. Brass finish would be nice.

[jinx2350]

So a little more catch up...
I forgot to mention in the last post that Paulages also sold me a really nice seat from what he thought was a '78.  Screaming deal! about a 1/4 the price of even a repro cover from ebay.

I also got bored and rattle canned the side covers because they were a primer color that was vaguely the same as the tank, but had some cracks, etc. It's a Rustoleum product with a cool dimple finish. I dig it for temporary relief of primer sides.

Also ditched the grab bar, stock turn signals, and mirrors.  Just got some cheap-o stuff from Cyclegear for now.  Already broke one fo the Bikemaster Turn signals and replaced it.  God forbid you ever have to replace the bulb...i tried, it broke.


These mirrors. simple, and can see a quite a bit behind me.


That brings us to here:




Then craigslist strikes again.  I found 2 parts bikes, and a treasure trove of new and used parts.  Here's a teaser.  I'll list all the parts and start liquidating the stuff i don't want one day.

[Statenheimer]

Very nice looking bike.  I also like the patina.  I have my eyes on that exhaust for one of the 550's at some point as well.

Looks like you scored BIG on that CL buy, lots of in box parts in that one photo alone 

[jinx2350]

Very nice looking bike.  I also like the patina.  I have my eyes on that exhaust for one of the 550's at some point as well.

Looks like you scored BIG on that CL buy, lots of in box parts in that one photo alone 

I counted $500 in new parts in 4 items alone. Worth every bit of the $700 I paid.

I will say the exhaust sounds great.  The oil changes are going to be a pain, because mine are plagued with the same thing many of these design are plagued with.  Poor fitment (but doable) and pipes covering the oil filter.  That means wrestling the pipes on and off each time I need to change the filter.  I assume these were originally designed for someone doing a remote oil filter?

[jinx2350]

Been a minute, and I've been fiddling slowly with my bike.  Did a little fender chop on the rear, and painted it.

Also added an Emgo tail light from Dime City. http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-custom-motorcycle-electronic-lighting-parts-classic-retro-satin-black-taillight-62-21512-sbpc.html

 Upgraded to an LED from Superbrightleds.com
http://www.superbrightleds.com/moreinfo/led-vehicle-replacement-bulbs/1157-led-bulb-dual-intensity-25-led-motorcycle-bulb/170/767/

I'm pretty pleased overall!  I had some trouble getting the LED to run in the Emgo, but had to fiddle around with the contacts and make sure they aligned properly inside the housing. Now all is well!!

[DustyRags]

Cute. Let's get a side shot of that tail end? 

[davidtime]

Do you still have those parts bikes for sale?

[jinx2350]

Parts bikes are sold!  Sorry.   I still have the upgrade new parts due to put on.  Next small step will probably be the similar fender chop treatment to the front. 

I've got a long list of stuff to do on the front end that I may dive in and do, but summer seems to have come early to the Pacific Northwest, and I was too busy all winter to work on her.

[davidtime]

What are your plans on the front end? Learning about my first build as well so I try to suck up all the ideas I can.

[jinx2350]

What are your plans on the front end? Learning about my first build as well so I try to suck up all the ideas I can.

So far I have these following new parts to go on the front end:
-All Balls Steering Bearings
-All Balls Wheel Bearings
-All Balls Fork Seals
-Progressive Fork Springs
-New brake pads
-Slingshot braided Stainless steel brake lines
-Master Cylinder rebuild kit
-Oh...and a handy little Acewell Speedo/Tach Combo.  That's gonna be tricky, and involve both fab work and electrical, neither of which i'm very good at.

Also some additions/custom stuff:
-chop and paint the front fender similar to the back
-paint the forks the same black...maybe?

I'd really like to rebuild the wheels and paint them black as well, but new spokes sound kinda pricey.  I have all the above parts already waiting, and currently tight on cash.  So, we'll see.

[davidtime]

What electrical is involved with that speedo combo? Bracket should be fairly easy I would think.

[Bankerdanny]

Jinx, you should update your signature to remove the part about the parts bikes for sale, I would change it read "sold" since the early part of this thread mentions them.

[jinx2350]

Jinx, you should update your signature to remove the part about the parts bikes for sale, I would change it read "sold" since the early part of this thread mentions them.

True! Thanks for keeping me on the ball.

[jinx2350]

So I did a little updating.  Added some LED turn signals I found on Ebay.
http://www.ebay.com/itm/2-PCS-Motorcycle-Black-Universal-12-LED-Turn-Signal-Indicator-Blinker-Light-/230990028849?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item35c8142031



BTW: this Emgo tail-light is a total POS too.  Already had the ground wire rattle loose and pull out, attached a more secure crimped wire to the socket for a ground.  Plus the actual bulb socket took some fiddling to make the LED bulb work.  Looks good though. 

I was a bit skeptical, but for $15 it was well worth a shot.  I'm actually pretty impressed with the quality...besides the paint/coating.  These are actually all metal, which the add seems to leave out.  I was assuming for $15 they would be plastic.  Mounted them on the flat spot of my fender where I previously had some Bikemaster plastic signals.  Those things were junk.  The whole I had drilled was too big, these have an 8mm shaft I believe.  I used some scrap hose I had laying around, and placed it over the threaded shaft of the signal to take up the spare room.  worked like a charm, and I think the added "suspension" the rubber creates might actually help in the long run.

So to make the LEDs work properly, I added an electronic flasher unit, and the resistors.  Flasher is pretty straight forward.  Resistors were a new one to me.  I have NO clue how they work, just that many forum posts here said they were necessary.  Proof of my ignorance, I ordered 4...1 per signal.  Not necessary, you just need 1 per signal circuit. Oops.  These little orange guys here.


Got em here: http://www.ebay.com/itm/300641501278?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

I've heard you aren't supposed to mount these to plastic because they get very hot. I actually found this out after I had done the install.  But, the good news is they don't generate any heat unless the signals are ON.  Considering how rarely they'll be used, and the short duration of time I leave my signals on, I think they'll be fine.  I've run them for a couple minutes straight and felt them, and they don't seem to be hot enough to melt plastic. 

So far so good.

[DustyRags]

Lookin' good! Don't leave your blinker on when you're running a long straight!

[jinx2350]

Well my bike decided she needed to leak gas out of one of the carb overflows... a LOT of gas.  I was out for a ride, and parked it for about 10 minutes and came out to this.



My assumption is a stuck float bowl.  I've heard of this before, and know that a solid tap with a rubbet mallet will probably help. BUT, since I have some jets laying around, and wanted to re-jet for my exhaust I thought no better time than the present.  I dug in and removed the airbox...which is certainly tough, but I don't know what everyone whines about?? 

Then I discovered this...dangit. If you look closely, The #2 airbox boot from the left is a smidge shorter than #3.  that's probably not good.  I assume these are supposed to be the same.  I know I'm lucky to have an intact airbox, because complete and intact airboxes are hard to come by, but this puts a kink in that plan.  I also know that the boots for the 77/78 are different, and even harder to come by.



My question is...where do I get another one? This solution seems to have "dried up" ha. http://www.classicmotorcyclesolution.com/index.php?news&nid=6

I have a set up K&N pods, and I don't want to have to use them.  I'd prefer (after MUCH reading here on the forums) to keep the stock airbox set-up.

Moving along to the carbs.  I took them apart, and they are very clean after a sonic bath job last year sometime, but I did find a very small amount of oxidation/rust in the bowl of the suspected leaky carb.  Problem identified, and solved I believe. 



NOW, onto jetting....oh, the jetting question.  I've read plenty on here about it, and I know it's just going to be trial and error, but any advice would be greatly appreciated.  I've got 5 new sets of jets to play with.  93, 95, 98, 100, and 105 I believe.  I'm running the Stainless Yoshi replica pipes that I bought from Lossa Engineering.  I believe these are similar to the ones from GP MotorWerks, and likely superior to the Carpy pipes.  Anyway, I love them, and they sound great.  I've been running them for almost a year with stock jetting and it's OK, but has a very cold blooded nature.  Even on warm days, I have to warm the bike up on choke for a solid 3-5 minutes.  On cold days....sometimes over 10 mins.

Pulled my plugs, and did some research, and I think I'm a bit lean.  Also, pipes have turned quite "blue" right next to the engine.  I like the color, but I know it's also indicative of running lean.  Anyone have an opinion?? All my plugs are thankfully a similar, so i'm running pretty even across all 4 cylinders. More Tan than White.

[iron_worker]

That porcelain looks very white which is an indication of running lean. Blue headers are another indication of this. It means your exhaust gases are getting VERY hot. I'm no sure if you mentioned what jet size you're running now but I'd got up 2 steps and check plugs again. It's better to be rich than lean.

I would think if it was running that lean it would bog badly?

IW

[jinx2350]

That porcelain looks very white which is an indication of running lean. Blue headers are another indication of this. It means your exhaust gases are getting VERY hot. I'm no sure if you mentioned what jet size you're running now but I'd got up 2 steps and check plugs again. It's better to be rich than lean.

I would think if it was running that lean it would bog badly?

IW

Two steps from 90, would that be 95?  That's what I was thinking about starting with.

[iron_worker]

Start there and see what happens. Do another plug chop.

IW

[jinx2350]

So...I ordered the wrong jets. 

If anyone needs jets for some keihin carbs, they're for sale HERE: http://portland.craigslist.org/mlt/mcy/3897474754.html
It's these jets: http://www.psep.biz/store/keihin_main_jet.htm

It very plainly says "PD" carbs, but not pd46, or anything about CB550.  Lesson learned.

New jets ordered from Z1, and they were much cheaper. 

I went with 100 Main Jet for now, and changed my bowl gaskets for good measure, and reset my mixture screw to 1.5 turns out.  When I went to turn them in to reset, they seemed to be turned out about 3-3.5 turns.  Not sure if previous owner, or mechanic did that?  Might be necessary.

Put everything back together, and it fired right up with a lot less choke time than before.  quick little rev through the throttle range already shows some signs of being sluggish and lower RPMs.

Now I have gas leaking from #1 bowl or mixture screw.  I'll fiddle with the bowl again to see if I messed up with seating the gasket.

Question: I know I need to vacuum sync with the new jets.  But, is it safe to ride across town to a place to use a sync, or will I being doing any damage?

[iron_worker]

I don't think you'll damage anything with the carbs out of sync. Mostly it will just run rough if it's out of sync.

IW