Topic: 1977 CB550F IDK (first build)

[minimo]

I wanted to put the clutch cover on but came across something...

How tight is tight enough on the clutch springs? Are they to compress to maximum compression? I see how the clutch lifter plate  affects the movement of the clutch lever so just wondering...

[mrtanner101]

I'm actually looking for the stock airbox setup and the gas cap and fuel petcock and possibly the seat / hinge and lock, whenever your ready to offload some stuff let me know.  I work on my bike each winter, and sooner or later I will have everything I need for it. when I got it It was only about 75 percent there, im around 90 now lol.

[minimo]

I hear ya, mrtanner101. Will keep y'all posted.

Meanwhile, I'm still stuck on the clutch basket springs. How tight do the bolts have to be before I can put the cover back on?

[zenocchio]

dont over-tight them, otherwise they will snap.
the bolts will not back out when the cover will be in place.

[minimo]

Thanks, zenocchio! What I wanted to hear 

dont over-tight them, otherwise they will snap.
the bolts will not back out when the cover will be in place.

[minimo]

I swear, it's like two steps forward, one step back -- ALL THE TIME. I had my doubts about how I installed my pistons so just to make sure I had to peel back the cylinder head to make sure that the pistons all had the arrows pointing in the right direction (toward the exhaust). So they were. Phew. With the cam exposed again, I was able to correctly align the chain/sprocket and turn the notch (facing to the right) so that it aligned with the "T" at top-dead-center. After torquing the bolts back down I adjusted all the valves and gave a light polish to the tappet covers to get those screedw back on along wih the intake manifolds and the clutch cover.
Ordered a bunch of O-rings for the oil filter, oil pump, starter, etc.

Examining some of the exploded views I then caught my eye on the 2 crush washers (part# 90485-001-000) that go under the cylinder head side cover settings. Mine had been crushed into the cylinder head so I had overlooked them. I've been reading that these shouldn't be reused but I've been scouring the webs and can't find any replacements as the part is seemingly obsolete. A bryanj on the forums suggested part# 90441-028-010 but it's a 6mm washer... Will that work?

[minimo]

So I decided that I won't be powder coating my frame or any other parts mainly for budget reasons and convenience, but also because I want to carry this project through with the idea that I've done everything myself (at least so far) damnit!

Since the frame and swing arm won't be put under high temp (for powder coat) is there any reason why I should replace the swing arm bushings if they appear ok? Reading through the forums, it sounds a bit nightmarish to replace the bushings... Nevertheless, I just want to know if I should do it while I have the parts to do it and while it's an opportune time since everything is off at the moment. I'm trying to cut any corners now while I'm ahead. Ha.

[wnyoutlaw]

So I decided that I won't be powder coating my frame or any other parts mainly for budget reasons and convenience, but also because I want to carry this project through with the idea that I've done everything myself (at least so far) damnit!

Since the frame and swing arm won't be put under high temp (for powder coat) is there any reason why I should replace the swing arm bushings if they appear ok? Reading through the forums, it sounds a bit nightmarish to replace the bushings... Nevertheless, I just want to know if I should do it while I have the parts to do it and while it's an opportune time since everything is off at the moment. I'm trying to cut any corners now while I'm ahead. Ha.

I'm replacing my swing arm bushings as well as all the wheel bearings, steering stem bearings, etc now while I'm in the mode. I'd rather do it all now while my bike is torn apart as opposed to wishing I had in the Spring when the weather is nice.

[minimo]

That's a good point, wnyoutlaw. Thank you. Now is the time to push those puppies out. Let me know if you come up with any cool tricks and I'll do the same. Good luck!

[minimo]

Homemade shock bush puller.
Used a 3/8 x 5.5" hex bolt, an oxygen sensor socket that fit perfectly on the O.D. of the bush, and some washers that luckily fit around the bush. Added a 3/4" hex nut to beef up the push side, sandwiched with another washer. Torque down with a couple of wrenches making this an easy push out. If only the swing arm pivot bushes would be as easy; got the hacksaw on the ready. Not really looking forward to sawing but I'm determined to do it one way or another. Still the slowest build... Stay tuned

[minimo]

Behold, my badges of swing arm honor.
This wasn't as tough as I thought, actually. Thanks to you guys and the info found here, I employed the 12/6 o'clock cuts on the pivot bushes and that seemed to be enough for my trusty Harbor Freight slide hammer to bang out the rest.
Next up, sand/clean up the swing arm along with the frame and other (aluminum) parts. Then wash/dry the parts with white vinegar followed by a generous application of gun bluing, and then an automotive clear coating to seal it all. Going for a raw patina'd steel look. See how it goes. Since I haven't quite thought this all through completely (just thinking/writing out loud) I guess I should probably also go ahead and bleed/clean the front forks, swap out the springs/oil, maybe even prep some of the front/rear fork parts for some bluing? Oh my, still a long way to go. I haven't even tackled the rebuild on my carbs yet! Kill me now.

[minimo]

I want to replace the bearings on the front (and rear) hub but before I can get to the bearing retainer I'm having the most difficult time trying to unscrew the front axle nut. I don't own a vice so how do I keep the axle from spinning as I try to wrench the nut off? Lefty loosey, right? Put heat on the nut? I've exhausted the search here on the forums too...

[minimo]

Whoops. Would it have been better to keep the spokes screwed in the wheels?

[Trevdawg]

i have been reading this while i am at work... its addicting. You seem to be making great progress even if it is taking a while.

I am thinking about taking on a simliar challenge with the same engine, but 1976. The bike has no tank, seat, fearings, carbs, and has been sitting outside against a tree for atleast 8 years now.....
The no carbs for such a long time is what has me worried the most. Spark plugs are stuck too.

Seeing this gives me motivation but i don't know.   

Keep it up!

[WhyNot2]

six of one......half a dozen of the other...................

same difference...............................you can do the bearing either way.

[edwardmorris]

I want to replace the bearings on the front (and rear) hub but before I can get to the bearing retainer I'm having the most difficult time trying to unscrew the front axle nut. I don't own a vice so how do I keep the axle from spinning as I try to wrench the nut off? Lefty loosey, right? Put heat on the nut? I've exhausted the search here on the forums too...

I ran into the same thing, ended up building a second workbench and buying a vice at a sale at menards. Desperate times, desperate measures but I got all the bearing out.

[edwardmorris]

Whoops. Would it have been better to keep the spokes screwed in the wheels?

Don't think it matters, the wheel will keep spinning even when the axle is locked down in the vice. The real kicker was what I used to twist the damned thing loose, the squeeze rod from a silicone tube thingy.

[minimo]

Don't think it matters, the wheel will keep spinning even when the axle is locked down in the vice. The real kicker was what I used to twist the damned thing loose, the squeeze rod from a silicone tube thingy.

Thanks for your input, budlite282, and for the photo also, edwardmorris.
I've been holding back on a vice purchase because I don't have space nor a proper work surface to mount one, BUT, like this bike project has proven to me time and time again, there will always be a way to make it work. I'm going to do some research on some clever ways to make either a collapsible yet sturdy work bench to mount a vice or somehow rig a detachable unit. I'm about due for a Harbor Freight and Home Depot visit anyhoo. If you have any ideas for a sturdy vice mounting solution in a limited space (or pics) please post or link me to them.

Thanks for tuning in, Trevdawg. It pleases me to hear that my project has captivated you so. But what do ya say you help fund my bike project rather than get compensated for the "work" you're supposed to be doing… Doh! But seriously, I think you have two choices: begin work on your bike or just sell it the way it is. Seriously, those parts that you mention are actually the most common ones talked about and replaceable (relatively cheap) and as you know there's a wealth of info and helpful folks here and elsewhere to give you pointers. There's really almost no excuse not to do it. The going mantra has been you never know until you find out.

[edwardmorris]

Just swing by the auto shop where you get an oil change or something, they ought to have a vice somewhere you can use for a few.

Ideally you should have one, its almost essential when it comes to crap that won't cooperate (stuck front breaks anyone?). If its a space issue, you MIGHT be able to get away with one of those grinding/polishing pedestals, but you'll have to anchor it down super sturdy somewhere.

[minimo]

Thanks, edwardmorris.
Looking at a bullet-style Wilton… Oh, so nice! Ideally, I'd like like to be able to really bear down on it and be able to press fit parts. But one can dream. I'll keep on the Craigslist search for a decent bench vise. Meanwhile, I like your idea of rolling the ol' hub to one of the local mechanic's shops…

[minimo]

Finally disassembled and ready for some cleaning and replacing the springs/seals on these suckers.

It wasn't too easy getting here though. I had to mock up the triple tree and clamp the forks back in to loosen the top bolts. Remember to loosen the top bolts (don't remove them all the way or else the spring will shoot out with oil) before sliding the forks out of the triple tree.
Always something to make this build friggin' challenging. Put a fork in me.

[minimo]

The Year Of The Axle Nut


A serious bear of a removal project. Like the Sword In The Stone - who is the mightiest warrior to remove this friggin' front wheel hub axle nut?
I still don't have a vise so after toiling on the living room floor trying to clamp down vise-grips and crescent wrenches, slipping and flying all around, I got fed up and sought the help of some pro auto mechanics today. After being led from one shop to another - all have been so gracious - it finally took one place to get the damn hub in a large vise, and by sandwiching the flats on the end of the axle with some small metal square stock, and with a large ratchet and deep socket, veins bulging from his forehead the burly mechanic raised up and then down to loosen the darn thing. And with a thick Russian accent says to me, "You must know how to use some tools."

Ok.

[calj737]

I recently tore down a very neglected bike where every nut, bolt and piece of metal was rust-encased. A bit late, BUT next time loosen the axle nut before you remove it from the forks completely. Having it still attached to the opposite side fork, it still in the bike, provides a great deal of leverage. Penetrating spray and heat, and she'll come running.

[minimo]

Thanks, calj737. In hindsight, yes, exactly what I was thinking :-) Next time :-)

[calj737]

I gotta work on my Karnak powers.... Sorry about that