Author Topic: Honda CB500 1975 restoration (Read 10919 times)

Mace · « **Reply #25 on:** September 10, 2016, 04:38:34 AM »

So I've made the decision to split the engine myself. I figured with a bit of common sense and patience I can do the job myself.

I also decided at a spur of the moment to cut the rear foot peg mounts off.

I got everything attached to the engine blasted, and I'm going for an aluminium look with gloss black on the cylinder block.

I'm also doing a 1mm overbore due to some pitting damage. I tell you what there aren't very many kits for the 500/4. Lots for the 750, 550 and 450. But not many for mine. I had to get one ordered from Japan. I was going to go for the 4mm overbore bringing it up to 553cc, but I bottled it on the price

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calj737 · « **Reply #26 on:** September 10, 2016, 04:43:54 AM »

CruzinImage makes a 59MM kit with rings for $120. Bore the motor and pop them in. Finished.

Mace · « **Reply #27 on:** September 10, 2016, 05:28:13 AM »

Damn, shouldve posted this update before I went and bought the kit!

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Mace · « **Reply #28 on:** September 20, 2016, 12:44:18 PM »

So I've been quite busy over the last few weeks. Since getting the engine blasted, the 57mm piston kit has arrived from Japan.

Furthermore, it's amazing how indecisive I've been about how I want the engine to look. I ended up painting the crank case and cylinder head in aluminium, but I wasn't happy with the finish. So I went and stripped it all off. I've now painted it black, and I'm going for a high polish finish on the clutch and sprocket covers.

The next task is to get the cylinders overbored so I can start to rebuild the engine in the frame.

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calj737 · « **Reply #29 on:** September 20, 2016, 01:10:50 PM »

before you put the motor in the frame, and before you install the valve cover, torque the head, wait overnight, and release/re-torque the head. This can be done in the frame, but easier outside it. You're not saving yourself much time or trouble by installing the engine prior to finishing the build. It will go in complete or in stages just as easily.

cantarauk · « **Reply #30 on:** September 20, 2016, 01:21:56 PM »

Hi Mace,

It is looking good and I know what you mean as I keep having a change of mind when it comes to engine appearance. For your bore job where did you get this done as I am struggling to find someone up here in Yorkshire or at least who is not going to charge over the odds.

G

Mace · « **Reply #31 on:** September 21, 2016, 03:46:28 AM »

I went to a professional engineer in Slough.

www.hthoward.co.uk

Wasn't cheap though, around the 200 mark for the overbore, as well as getting a good fit on the cylinder head. A friend from work has used him before and he said he is the best man in the south East for engine restorations.

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cantarauk · « **Reply #32 on:** September 21, 2016, 12:46:22 PM »

Cheers for the details Mace.

They look like a really well setup machine shop. Wish I could find a professional outfit like this up North. May be cheeky and ask them if they know of any reputable guys

calj737 · « **Reply #33 on:** September 21, 2016, 12:50:35 PM »

Have you posted this query on the U.K. SOHC site yet?

cantarauk · « **Reply #34 on:** September 21, 2016, 01:00:12 PM »

Hi Calj737,

Just busy re-posting over in uk site. Also just wanted to ask you is the calliper on your CB550 standard just coated red ?

Mace · « **Reply #35 on:** September 21, 2016, 01:44:39 PM »

Gents I have reposted this thread over on the UK site, so any future updates will go on there. I will of course bring back the finished project once I'm happy with it.
All the best.

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calj737 · « **Reply #36 on:** September 21, 2016, 01:55:33 PM »

Caliper is standard, powder coated in red as you suspected. Don't abandon us for the Brit site! Just might dual post pleas for local resources when you need them

cantarauk · « **Reply #37 on:** September 21, 2016, 02:24:54 PM »

Not jumping ship, don't worry

calj737 · « **Reply #38 on:** September 21, 2016, 03:47:07 PM »

I thought the Brexit included all SOHC builds

RAFster122s · « **Reply #39 on:** September 21, 2016, 10:41:59 PM »

G, I kind of got the meaning of "over the odds", but that one I don't recall hearing it ever used in the US or in my many interactions with Europeans. I am certain we Yanks have expressions that puzzle you as well.
David

Mace · « **Reply #40 on:** September 21, 2016, 11:40:16 PM »

Provided the banter is free flowing, all our conflabs should be without any bother!
;-)

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cantarauk · « **Reply #41 on:** September 21, 2016, 11:52:16 PM »

Originally from South Africa and moved to UK 15 years ago. Must a SA saying

cantarauk · « **Reply #42 on:** August 03, 2017, 11:46:44 AM »

Mace -

How is the build coming on or are you done ?

G

Mace · « **Reply #43 on:** September 03, 2017, 01:30:46 AM »

Its been a while since my last post so I have a few updates.

I've finished rebuilding the engine myself with brand new stainless Allen bolts and seals etc. I found the lower crankcase by far the hardest part. Getting the gear selectors in was tough.

However I stripped an already damaged thread on the lower crankcase on the lower oil cap on the offside of the bike. Given that it appears to be just a drain plug I have slapped some high temp jb weld in there for the time being.

I'm now in the process of building the wiring harness myself. New pamco electronic ignition went on which I got from the good blokes from 4 into 1.

Not long now.

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calj737 · « **Reply #44 on:** September 03, 2017, 04:20:36 AM »

Did you check for tire clearance until your seat hoop while under full compression? That looks like it will be really close $:-\$

Mace · « **Reply #45 on:** September 03, 2017, 11:40:49 AM »

That was something I was worried about, so I angled the tray skywards as soon as I could. Hopefully

the tyre will scrape through!

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Mace · « **Reply #46 on:** September 21, 2017, 07:58:33 AM »

Hey guys

After over 20 years sat rusting and feeling sorry for herself, I have finally got the old girl started! Very chuffed.

She runs really well, and sounds great with the 4 to 4 drag exhaust I made up.

Carbs are all synced and work great together.
She fires up straight off the kick even on a cold start.

However, I didn't think that my first engine rebuild would go smoothly and I do have a problem which im struggling to figure out.

The #1 cylinder is smoking quite a bit but only one the bike is fully warmed up. Nothing on cold idle or light revving from cold. Its a combination of blue and grey smoke and is definitely an issue.

Compression tests across all 4 cylinders :
1- 150
2- 155
3 - 150
4 - 158

After 5 mins of idle and revving these pictures are what I discovered:

Still image from a video I took.

End of the exhaust.

Exhaust valve.

Wet oil from the exhaust hole.

But the spark plug looks ok?

I've been reading reading checking and struggling to figure out what the primary cause may be.
I'm running the carbs lean on 3 turns out due to the pods and 4-4 exhaust.

The previous topics on here point to leaking oil around the piston rings and leaking oil from the valve stem seals. But both are brand new.

I'm running an electronic ignition with brand new dr8es ngk plugs and ngk caps and leads.

Any ideas at all?

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Author Topic: Honda CB500 1975 restoration (Read 10919 times)