Author Topic: CB550 revamp  (Read 22453 times)

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Offline Bankerdanny

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Re: CB550 revamp
« Reply #75 on: June 13, 2013, 12:02:39 PM »
I just buy the standard oil resistant grey gasket material. I don't believe that the clutch cover is sensitive to the tiny variance in thickness between the various gasket materials.
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Current: '76 CB750F. Previous:  '75 CB550F, 2007 Yamaha Vino 125 Scooter, '75 Harley FXE Superglide, '77 GL1000, '77 CB550k, '68 Suzuki K10 80, '68 Yamaha YR2, '69 BMW R69S, '71 Honda SL175, '02 Royal Enfield Bullet 500, '89 Yamaha FJ1200

Offline spdygnzlz

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Re: CB550 revamp
« Reply #76 on: June 19, 2013, 04:11:16 PM »
Found a NOS gasket for the 74 550 so my laziness won out again.  Also ordered the new chain/sprockets combo from Krauss Racing:  http://sidewindersprockets.com/index.html  Got the stock 16T and custom 39T in High Carbon Steel since Titanium seemed a lot over the top.  Also making the switch from 530 to 520.  Slow progress but still progress!


Offline spdygnzlz

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Re: CB550 revamp
« Reply #77 on: June 20, 2013, 01:06:16 PM »
Does anyone know the part number for the rubber grommets on the alternator wire going through the alternator cover and the left side cover near the oil pump?  I can't find it identified anywhere and I need to find a replacement if available.  Mine is crusty and broken. 

Offline RAFster122s

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Re: CB550 revamp
« Reply #78 on: June 20, 2013, 04:07:08 PM »
spdygnzlz,
Most I've seen was folks using an RTV silicone to replace this. It can be trimmed afterwards to make it a little cleaner install and you could use tape on the covers to keep it from sticking... Or give yourself an edge to trim to.
Just have to take care to locate the wires in the middle of the RTV. Bit of shrinkwrap or a small rubber band might do the trick to keep them bundled tightly.
David- back in the desert SW!

Offline spdygnzlz

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Re: CB550 revamp
« Reply #79 on: June 20, 2013, 07:35:49 PM »
I think I should be able to salvage it...it won't be pretty but I also didn't realize it's molded on.  Anyway, working on the electrical system and integrating the Motogadget M-unit into the system.  Anyone know if it replaces the Starter Safety Unit?  I know it's a shot in the dark but I thought I'd ask here.  I'd love to simplify the wiring as much as possible and from what I've read, the SSU isn't used in later models...

Offline spdygnzlz

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Re: CB550 revamp
« Reply #80 on: July 02, 2013, 08:28:42 PM »
Did some more work on it today, started sealing up the top and realized that I'm missing one of the round pucks between the head and the rocker assembly.  Anyone got a spare?  I can't remember if there were 6 in the original packaging but all I have in the baggy now is 5.  Odd.  I remember putting them in individual baggies when I separated the "top end kit" so they should all be there.

Offline spdygnzlz

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Re: CB550 revamp
« Reply #81 on: July 08, 2013, 07:26:22 PM »
Got more parts back from powdercoating etc. Now trying to install the kickstart and shifter rubbers on but not having much luck.  Is there a trick to it?  I can get it started but neither one gets any further than that...

Offline FunJimmy

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Re: CB550 revamp
« Reply #82 on: July 08, 2013, 09:17:49 PM »
Got more parts back from powdercoating etc. Now trying to install the kickstart and shifter rubbers on but not having much luck.  Is there a trick to it?  I can get it started but neither one gets any further than that...

I'd try soap and water. Lots of soap.
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Offline cheftuskey121

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Re: CB550 revamp
« Reply #83 on: July 08, 2013, 09:26:43 PM »
Got more parts back from powdercoating etc. Now trying to install the kickstart and shifter rubbers on but not having much luck.  Is there a trick to it?  I can get it started but neither one gets any further than that...

isopropyl alcohol or hairspray works wonders. just let it dry for a good bit before you start cranking away on them

Offline spdygnzlz

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Re: CB550 revamp
« Reply #84 on: July 08, 2013, 10:56:13 PM »
Thanks guys.  I found a lot of grunting and cursing could do the job as well, though now my thumbs feel like they're separating from my fingernails.  Good times.

I realized during the weekend that I had forgotten to have my upper and lower triple clamps powdercoated along with everything else so I dropped it off today.  Why make the trip to the powdercoater when I can do it multiple times and pay for multiple small batches?  At least he's being nice to me now and taking it a little easy on my wallet. 

On a side note, while I was rebuilding my bar controls, I noticed that the clutch was not connected to anything.  Looked like the orginal cable had broken long ago.  Now, my bike has one of those SSU (starter safety unit) and from what I understand, the SSU makes sure that the bike is in neutral, clutch is pulled back etc before allowing the bike to start.  Is that right?  Does the clutch switch not being connected automatically default to letting the bike start?  My plan is to discard the SSU entirely and simplify the wiring as much as possible with the M-unit and a fresh custom harness...


Offline spdygnzlz

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Re: CB550 revamp
« Reply #85 on: July 12, 2013, 06:28:12 PM »
Did more bondo and sanding work on the tank and sidecovers today while I wait for the moto shop across the street to install new seals on the forks.  Decided against any logo/emblems so if anyone out there is interested in the set, let me know.  They're in ok shape but could definitely use some love.  All I ask is some coin for beer and postage for both the tank and side cover badging. 

Offline spdygnzlz

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Re: CB550 revamp
« Reply #86 on: July 15, 2013, 02:14:27 PM »
Paint work done.  Color is Nara Bronze Metalic.  I got it from Auto Color 66 in a custom Spraymax 2k spraycan.  2 Coats of gloss clear coat on top.  There are a few spots where dust got on but it should all buff out.  I think it looks pretty nice, much better than the worn out orange flake that was there before. 

Offline spdygnzlz

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Re: CB550 revamp
« Reply #87 on: July 22, 2013, 10:18:38 PM »
Anyone know what footpegs will work with the stock mounts?  I want to replace the chunky steel/rubber stock ones with aluminum ones if there's a viable and safe option. 

Offline iron_worker

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Re: CB550 revamp
« Reply #88 on: July 23, 2013, 06:55:43 AM »
Oh my! I really like that color.  8)

IW

Offline cheftuskey121

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Re: CB550 revamp
« Reply #89 on: July 24, 2013, 06:05:22 AM »
That color is gorgeous man!

Offline spdygnzlz

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Re: CB550 revamp
« Reply #90 on: July 29, 2013, 08:53:49 PM »
Thanks!  It turned out better than I expected considering I sprayed it on the sidewalk.  It can use a little superfine wetsanding and polishing but that will be when everything is dialed and done.  Overall, very happy with it though.

I got around to glassing up another seat pan since my first one was too snug on the frame and didn't have any room for upholstery. The new one looks much better and is much lighter since I realized I didn't have to make it so thick. 

Still waiting for the forks to get the seals on but did get a consolation prize today with the new 520 sprockets and chain conversion arriving from Sidewinder Sprockets.  I couldn't help myself and got the gold chain.  Pics of the parts in the am.  Hopefully I can get a few hours into the bike before the lady and I bounce out of town for a week and a half in Costa Rica.

Looking forward to finishing this project up and cleaning up the shop.  Once it's all done, I'll need to find a home for all the old parts I didn't use.   

Offline spdygnzlz

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Re: CB550 revamp
« Reply #91 on: August 11, 2013, 08:38:28 PM »
Quick question, how does one fit the cb750 carbs onto the cb550 engine/frame?  It doesn't seem to clear and before I go and bend the wrong thing up, I figured I'd post here. 

Thanks in advance!

Offline spdygnzlz

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Re: CB550 revamp
« Reply #92 on: August 20, 2013, 11:26:03 AM »
Found this in my box of parts.  Anyone interested, make me an offer!  Looks to be in very good shape.

Offline spdygnzlz

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Re: CB550 revamp
« Reply #93 on: August 29, 2013, 03:54:55 PM »
I checked with Dyna and they told me this ignition is indeed for older Hondas and it will fit the 1969 to 1978 Honda
500/550 and 750 four (4) cylinder motors. 

Offline spdygnzlz

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Re: CB550 revamp
« Reply #94 on: September 17, 2013, 10:36:25 PM »
Pictures soon but here's the current update.

Took a few tries, but got the cb750 cable hanger modified cleanly to work with the 650 head and still clear the frame.  I ended up cutting the push cable stop and having it rewelded a little bit further up and back on the arm.

Wiring is 90% done now.  Pretty much took the old electrical panel and tossed it, old reg and rect are available if anyone in interested, they still work.  Wired in the Acewell digital gauge, Motogadget M-unit, Motogadget M-lock, new reg & rect, Radiantz LED blinkers.  Also rebuilt/repainted and cleaned up the controls, removed some wires that were no longer needed and cleaned up all the internals.  I wired up the headlight to be constant on instead of switchable so now I have an extra switch in case I want to add something later.  I Couldn't find a NOS red kill switch toggle so I just repainted it in red Testors model enamel.  Now I just have to figure out how I want to route and mount the speed sensor.  I could probably do something stealthy on the rear end/wheel...

Overall, very impressed with the M-unit, I think I could have probably wired the control switches with cat5 cable since it runs really low voltage on that side.  I may test it and do that or something similar in the future.  Would be nice to streamline the wiring even further.  It comes with burly power cable that I may use for the starter solenoid instead.  It seems overkill for powering the rest of the bike...  I mean, it's a 6awg wire!  Does anyone make an inline ATC fuse holder with leads that big?

Highlights of the M-unit:
1. disables the headlight until either I hit the starter or manually toggle the high beam.
2. auto cancels the indicators in case I forget to turn them off.
3. can be set to flash the brake light.
4. easy connection to M-lock
 
Sorry if that read like Motogadget's catalog.  It really is cool stuff...just a wee bit expensive. 

Offline spdygnzlz

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Re: CB550 revamp
« Reply #95 on: September 18, 2013, 11:25:17 AM »
Motogadget and throttle cable hanger installed.  Mounted up the throttle cables and throttle grip. 

Offline spdygnzlz

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Re: CB550 revamp
« Reply #96 on: November 15, 2013, 12:17:17 AM »
Been super slammed with work so no progress on the bike for a while.  The only contact I've had is in order to move it out of the way in the workshop.  I finally had the chance to check the carb fitment more to see about carb clearance on full throttle and how I'm going to handle the petcock placement.  Then I got distracted and ordered a set of CR29s.  So, I'll likely be selling my freshly rebuilt 750k carbs with brand new (still in plastic) KN pods.  The hanger was modded to fit the 550 frame and 650 head but those are relatively easy to pick up if you're not planning a 550/650 hybrid motor...  I'll sit on it for now and ponder the options and how I arrived at this point of the road.  I started as a "fix that oil leak" repair...lol

Sometimes I think I have more fun making things complicated and buying shiny things than I do trying to finish this project.  The bike has already been apart for over a year, what's another year or two?!

Offline spdygnzlz

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Re: CB550 revamp
« Reply #97 on: December 09, 2013, 10:14:03 PM »
More things going on.  I got the CR29s in and installed.  Had to shave down the pod flanges on #1&4 to clear the frame.  Also sourced some nice skinny hose clamps from Mcmaster Carr in order to make it work.  They have ones that also fit the factory rubber manifolds nicely so I got those as well.  I have maybe a few mm's of clearance now. 


Offline spdygnzlz

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Re: CB550 revamp
« Reply #98 on: December 09, 2013, 10:16:12 PM »
Also, I picked up the upholstered seat pan this evening.  Leather.  Sweet!  Now, just have to figure out how to do the grips in the same leather...

Offline spdygnzlz

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Re: CB550 revamp
« Reply #99 on: December 09, 2013, 10:18:35 PM »
One other thing, does anyone in or near the SF Bay area know of a place or person who could move the fuel tap on the tank?  I want to move it so the petcock can clear the carbs…