Author Topic: Honda CB550 cafe racer build (barn find conversion) (Read 29593 times)

Sherlock · « **on:** July 11, 2012, 08:17:15 AM »

Hi all, I posted an intro in the relevant section just to explain a little about what I'm doing.

So, this topic is to detail my CB550 1977 f2 Supersport project. I have chosen to rebuild it into a cafe racer.

I am updating a blog most days, mainly for the purposes of keeping a record and for anyone who's interested in following, commenting or even laughing!!

Here's the link to the blog - acaferacerisborn.wordpress.com

I have already begun stripping it down, and already been faced with a few minor issues.

I hope to gain a lot of experience from this and of course, valuable advice from members. :-)

Can anyone advise if it's worth trying to start the motor before I strip the bike, if so what is a recommended pre-start procedure for a bike that's been in a barn 15 years!!

...or should I just strip the engine out and dismantle / inspect and/or replace worn components as necessary.

Thanks for now

I will update and transfer my posts from the blog to here shortly.

Ride safe

flybox1 · « **Reply #1 on:** July 11, 2012, 09:25:47 AM »

id sure hate to get a bike all pretty and put back together only to find out the motor is shiit.
make it run, well, first, then you'll know if you need to re-direct funds to the engine build.
download the shop manual from the forum, and do a complete and thorough 3000 mile tuneup.

Mcwilliams570 · « **Reply #2 on:** July 11, 2012, 11:36:26 AM »

Yeah agree with flybox would suck to have it all together and it doenst run.

Matt

Sherlock · « **Reply #3 on:** July 11, 2012, 12:18:22 PM »

Thanks guys. That's decided then.

Sherlock · « **Reply #4 on:** July 11, 2012, 02:24:31 PM »

Can anyone enlighten me on what the best procedure would be to get the bike started.

My theory was;

Remove carbs and soak in carb cleaner or fresh petrol? (or do I need to strip and clean using a service kit even though this is on the agenda once I know the motor is running)
Replace carbs
Set up a temporary fuel tank using an ally drinks bottle and tap.
Use clear hose
Check plugs and points and clean
Put small amount of oil in spark plug holes
Replace engine oil (smells of petrol)
Kick the bike over several times to circulate oil to the head.
Check plugs are firing
Open throttle slightly/choke
Kick over
??

Sherlock · « **Reply #5 on:** July 12, 2012, 06:18:10 AM »

I removed a few things today :-)

The air box, battery cage, rear fender assy and carbs.

I wonder if anyone can comment on suggestions re. The rear seat supports. The left side has rusted away on the inside of the top rear fender/seat support
Next job is to clean the carbs. Do I need a complete kit or just gaskets??

Left rear, only the seat support bracket is corroded the frame appears okay having ground some paint off.

Right hand side seems okay other than a bucket full of Hamerite all over it :-/

Any advice welcomed. :-)

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Duanob · « **Reply #6 on:** July 12, 2012, 11:01:42 AM »

I also hate to see a perfectly restorable 550 F model bastardized into just another cafe "racer" . They are getting hard to find in original shape any more.

Sherlock · « **Reply #7 on:** July 15, 2012, 08:07:41 AM »

Carb heaven or hell?

Managed to start stripping the carbs today. Just waiting for an ultrasonic cleaner to turn up that I ordered to give everything a bath!

Service kit ordered, new jets, gaskets etc.
Do I need to replace the "O" rings joining the fuel pipes between the carbs when reassembling?

And any good links on bench setting the carbs up?

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Sherlock · « **Reply #8 on:** July 16, 2012, 12:29:31 AM »

Can anyone tell me the size of the fuel line for the carb to tank and the size of the fuel feed hoses on the carbs?

And what size is the drain hoses?

Thank you

Gman · « **Reply #9 on:** July 16, 2012, 06:25:12 AM »

Tank to carb is 5.5mm ID. It's not too common, and I've seen some 'discussion' (as there always is) about what people use instead and how it works/doesn't work/can't possibly work, etc. I just went to a local Honda shop and bought some (spendy at something like $3/foot), but it's the right size and you don't need much and you should only be doing it once for the next 35 years...

Pretty sure the drain tubes are 3.5mm.

And, you probably only need gasket kits for the carbs (vs. a rebuild kit, which includes the brass bits). Gasket kit has all the o-rings, including the ones for the fuel 'T' that you mentioned. I'm doing my carbs right now and the jets, needles, etc. cleaned up nicely. People seem to have problems using aftermarket jets, as they aren't quite OEM quality and/or specs.

Good luck!
G

Sherlock · « **Reply #10 on:** July 16, 2012, 06:38:37 AM »

Quote from: Gman on July 16, 2012, 06:25:12 AM

Tank to carb is 5.5mm ID. It's not too common, and I've seen some 'discussion' (as there always is) about what people use instead and how it works/doesn't work/can't possibly work, etc. I just went to a local Honda shop and bought some (spendy at something like $3/foot), but it's the right size and you don't need much and you should only be doing it once for the next 35 years...

Pretty sure the drain tubes are 3.5mm.

And, you probably only need gasket kits for the carbs (vs. a rebuild kit, which includes the brass bits). Gasket kit has all the o-rings, including the ones for the fuel 'T' that you mentioned. I'm doing my carbs right now and the jets, needles, etc. cleaned up nicely. People seem to have problems using aftermarket jets, as they aren't quite OEM quality and/or specs.

Good luck!
G

Excellent. Thanks very much for your advice. Makes perfect sense now. Wish I had held back on ordering the service kits. Though I did notice a couple of the brass bits had at some point been fiddled with. (someone used pliers to get them out)
I've just ordered a complete gasket set would the o rings for the carb fuel lines be In there (for the T?) ?

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Sherlock · « **Reply #11 on:** July 17, 2012, 05:03:21 AM »

Can anyone advise on the bearing Retaining Ring thread on rear wheel. (CB550F)
Is it left or right handed.
Someone's been in there before and hacked away at it :-(

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Sherlock · « **Reply #12 on:** July 19, 2012, 03:53:34 AM »

Carb cleaning:
Overnight soaking in Motorex carb cleaner, 5mins in Ultrasonic cleaner and then buff and polish with a dremel.
And voila,,,

Before: (obviously!)

After:

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Sherlock · « **Reply #13 on:** July 19, 2012, 11:59:36 PM »

Does anyone have a good chemical recipe for cleaning carbs using an Ultrasonic Cleaner?

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Sherlock · « **Reply #14 on:** July 22, 2012, 12:56:15 PM »

Has anyone got any good tips in how to get a seized brake piston out the caliper other than smash it with a F'king big hammer :-(

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Mcwilliams570 · « **Reply #15 on:** July 22, 2012, 01:20:26 PM »

Try a grease gun or a air compressor if using the air comp cover it or something they have been known to fly out.

I dont think you want to use the FBH method..

http://forums.sohc4.net/index.php?topic=86873.0

Matt

Sherlock · « **Reply #16 on:** July 23, 2012, 10:32:55 AM »

Quote from: Mcwilliams570 on July 22, 2012, 01:20:26 PM

Try a grease gun or a air compressor if using the air comp cover it or something they have been known to fly out. I dont think you want to use the FBH method..

http://forums.sohc4.net/index.php?topic=86873.0

Matt

Thanks ;-)
Don't suppose you know what the grease nipple size is I need?

Mcwilliams570 · « **Reply #17 on:** July 23, 2012, 10:48:42 AM »

I think it was 10mm. I am pretty sure the link I left in my last response said the size.

Matt

Sherlock · « **Reply #18 on:** July 25, 2012, 02:07:16 AM »

Thanks Matt

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Sherlock · « **Reply #19 on:** July 25, 2012, 02:10:03 AM »

What's the best way to get a 15yr old very hardened tyre off the rim? Do I cut it off ?

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fastbroshi · « **Reply #20 on:** July 25, 2012, 09:12:25 PM »

Did you end up getting that boogered up bearing retainer out? If you haven't found out by know it's reverse threaded.

Sherlock · « **Reply #21 on:** July 26, 2012, 10:19:25 AM »

Quote from: fastbroshi on July 25, 2012, 09:12:25 PM

Did you end up getting that boogered up bearing retainer out? If you haven't found out by know it's reverse threaded.

I didn't bother mate. Found a crack in the brake lining and a dent in the rim so ordered a second hand wheel off a 9k bike. Not sure what to do with this one as there isn't much to salvage on it. :-(

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Sherlock · « **Reply #22 on:** July 28, 2012, 09:59:47 AM »

Fork seals done today and a quick polish.

Before/after

Yuk!!

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Sherlock · « **Reply #23 on:** July 29, 2012, 09:33:11 AM »

Can someone advise on splitting the hub from the brake disc. Does it simply come up apart? Or am I missing something.

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Ewan 500K1 · « **Reply #24 on:** July 30, 2012, 03:19:05 AM »

Hi Sherlock, once the six bolts are removed the disc should just fall off, so yep seems its seized on. I'd give it a soaking in WD and lightly tap roound with a rubber mallet.

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Author Topic: Honda CB550 cafe racer build (barn find conversion) (Read 29593 times)