Topic: dangerdave's Project CB550

[dangerdave]

Hey guys, new owner here of a `76 cb550k, complete with some awesome Easy Rider mods: sissy bar and small ape hangers.  I just picked it up last night for a not so paltry sum of $500, which was more than I wanted to spend ( isn't it always?) but I'd been looking for quite a while for a decent 550 and this one was local, owned by a friend who was also a mechanic, and turned over freely.

Little bit o` back story on this beast: the PO had bought it used in the early 80`s, complete with the Easy Rider mods, and drove it around the Midwest for a few years before moving out to California and parking it for close to 20 years. Unfortunately he did nothing to cover it, except keeping it in the partial shade provided by his 20' stretched dually 70's era Dodge van sporting a rear spoiler and 'sweet' graphics  .



There is a slight bit of rust, mostly just surface, which I'm assuming came from Illinois, but the sun damage on the paint and seat I'm sure are all California. Some slight transport damage comes in the form of two broken turn signal lamps (no biggie, will be replaced with some better looking, tighter to the frame ones). Tires are shot, of course. Spokes are rusty (surface) so not sure of their integrity/reliability. Will strip and paint them, and see how they turn out. Seat will definitely be trashed; will most likely try to keep this a two-up, but shave down the dimensions of the original seat.  I will definitely be going the cafe racer look, and I've got pics of a cb450 that I'm really digging, so it will be modeled after that.

This :



Into this:



 
 
First I've got to go through the 3k mile tune-up suggested on this board, and we'll see if I got a decent deal or not. Oh, was also thinking of doing a 650 can swap, but can't seem to find many available (eBay, craigslist, etc)

Thanks for letting me ramble! And based on the many threads I've already read, I value your guys input!

DD

[harisuluv]

If you can get it running then you will probably make out fine.  Seat looks done but you might want to hang onto it for the pan, you might be able to use it later or turn it into something.  Usually if they turn over then you can get it running in just a couple days!

[dangerdave]

I'll definitely hang onto the pan. Actually, I think a duct tape seat cover will have to do for now. With all those fancy duct tape designs out now, I'm thinking leopard print! 
 Updates on progress tomorrow with pics; I'm really curious as to what's gonna happen when I hook up a battery to this wolf.

[Itwillbefun]

Looks like you're about to have some fun! I like the look you're going for... I'll be watching!

[dangerdave]

Well, slight bit of disassembly today: seat, rear pegs, tank, mirrors, sissy bar all off the bike. Looks like ill have to drop the exhaust a bit to remove the crash bars. Stopped after a few too many beers after hooking up a fresh battery and finding out the headlight and side lights turned on, along with the neutral switch light and oil light. Starter didn't crank over, so will have to bust out the multimeter and manual impact driver on thursday.

id like to keep the stock airbox, but I'm not into smog equipment, so the little EGR assembly coming up from underneath is gonna have to go. There are enough Prius' around here to offset my miniscule amount of air pollution to soothe my conscience.

[dangerdave]

So, progress is slow, unfortunately, but a few key things were accomplished:

1. Seat removed
2. Tank removed
3.  Crash guards removed
4. Exhaust dropped and mufflers removed. In the picture, that was only HALF of the rust that fell out of the right side exhaust. It was mostly the inner baffling that rusted away, with only slight rusting of the actual pipe. The other side had zero rust, just soot)
5. Figured out why the electric start wouldn't work. The wires going to the button were completely deteriorated. I bridged the circuit on the starter solenoid(?) And she started to crank right over.
6. Removed 3 of the spatk plugs, 4th is proving tricky. Its the one right below the speedo cable, so its not exactly a straight shot. Will shoot some acetone/ATF mix tomorrow.

Oh, and it looked like there were 2 cables going from the throttle to the carbs. What gives?

[LesterPiglet]

You mean the plug under the tacho cable? Remove the tacho drive from the cover if it's in the way. The second cable is a safety feature to close the throttle if the carbs stick open.

[dangerdave]

Yup, that's gotta be it. Didn't bother to trace the wire. I'm fairly sure I'll be changing the throttle, so is the second cable a pretty standard feature on most bikes?

[LesterPiglet]

If the throttle grip has the provision for two cables then yes. Personally I have never used the closing cable cos I'm a rebel. 

[dangerdave]

What a badass you are, sir! 
 

[dangerdave]

Alright, back in action!!! After a very long hiatus involving sibling wedding plans and me being chosen as the brides  'Man of Honor' (no jokes! Haha). I've got the ball rolling again by getting the frame powdercoated, new tapered steering tube bearings installed, and new gauge faces designed. What do you think of the designs? (Bet ya dont recognize the design on the speedo!)

[MtnPwnd]

What program are you using to design your gauge face? I'd love to come up with a good design on my own for my project.

[dangerdave]

It was all adobe photoshop. Scanned the plates first,  then worked on those images so that the tick marks and size were all to scale and accurately placed.

[dangerdave]

Did a bit of spring cleaning in the garage today....painted pics to follow in the next day or so.
After steel wooling the hell out of it (tough chrome btw) i washed with soap and water, then Prep-All aerosol, wiped clean then followed with 2 light  and a medium coat  of gloss black engine paint. Gonna wait a few days to put back together for the paint to cure so i don't scratch the bejesus out of it. Next up: Engine degreasing and soda blast!

[dangerdave]

Painted and reassembled the springs. They turned out pretty well. Started disassembly on the front end; got the brake down to the pads then used a grease gun screwed into the brake line port and pumped that piston out! Got that great bit of knowledge from some posts on here. Thanks guys! (Though it scared the $#!+ out of me when it finally shot out of the caliper.


Piston doesn't look too bad...

[mono]

I'd replace it.  Mine was lightly pitted like that and didn't want to retract.  You can get a stainless one for about $30, never rust again!

Looking good so far though!  You're really going all the way! 

Sent from my SPH-L710 using Tapatalk 2

[Tews19]

Subscribed too!

Check out Godffreys work on here. He does excellent work and has done a few 550 builds. You can get phenolic( not sure if that's the proper spelling) pistons. Lightened and drilled rotors and other custom work for great pricing.

[dangerdave]

I think im just going to replace the brake piston rubber seal first and see if the fresh rubber will help seal against those pits. (Got a tight budget, but not afraid to tear back into the caliper if that doesn't work.) Thanks for the advice, mono

As for the rotor, I'll give drilling it a shot myself instead of farming it out right away. Not afraid of acquiring new skillsets.....or tools!  I'll keep Godffrey in mind though in case i run into any issues though, tews.

[mono]

I think im just going to replace the brake piston rubber seal first and see if the fresh rubber will help seal against those pits. (Got a tight budget, but not afraid to tear back into the caliper if that doesn't work.) Thanks for the advice, mono

good plan!  let me know if you're going to replace -- there's a guy here in Toledo that machines them for the local bike shop.  good prices.  they aren't phenolic, but mine works great.

[SF]

nice to see another going back on the road