Topic: RE: My $100 dollar CB500 - Thanks to everyone

[chewbacca5000]

Didn't quite make it to the electrics tonight spent half my time trying to locate all the frame bolts.  Was very happy with myself getting the forks on until I look down and some some rubber donut thingies that go into the fork ears.  O well at least know I know how to do those fork gaiters without too much trouble.

Also repaired the wiring harness where the ground wire melted.  Over all things are starting to move along.

[MJL]

I used to throw all my bolts in a pile thinking I'd remember which was which... Now I keep a box of ziploc baggies and a sharpie at hand when I'm tearing down. Label the bag, throw nut/bolts/whatever in it and throw the bag in another box with other bags. Makes it so much easier to put things back together. I also take pictures as I work, multiple shots and different angles. One other thing, a laptop and internet access is awesome to have at hand.

I'm watching this thread since I have a cb500 project in queue.

[chewbacca5000]

I used to throw all my bolts in a pile thinking I'd remember which was which... Now I keep a box of ziploc baggies and a sharpie at hand when I'm tearing down. Label the bag, throw nut/bolts/whatever in it and throw the bag in another box with other bags. Makes it so much easier to put things back together. I also take pictures as I work, multiple shots and different angles. One other thing, a laptop and internet access is awesome to have at hand.

I'm watching this thread since I have a cb500 project in queue.

Yeah your right about the labeling thing I will be sure to do that going forward.  I am going to be so happy when the rest of the parts come in this week, and things start to take shape.  Much more fun putting them back together than taking them apart.  If you look closely there is any oven behind the bike I may use this to powder coat odds and ends going forward.  If I get good results bigger oven.

[chewbacca5000]

Made some progress today got the swing arm on and the front end back together.  Now I am at the point where things need to be put back on.  The problem is that some of the things are so crusty and rusty I don't want to reuse them without cleaning or powercoat.

I would love to powder coat the shocks, but have no idea on how to take them apart.

Also, I scored a backup 550 engine w/ 5,000 miles for 60 bucks.  Has missing nuts, bolts and sprocket cover, but with my other engine I should be go to go.  Now I have two low mileage engines for this bike a 8,000 mile and a 5,000 mile.  The po of the 5,000 miles says it is a  runner.

Any here is some pics and any help getting the springs off the shocks would be appreciated.

[Vinhead1957]

Lets see the top.   I have wood clamps and used a holesaw and some plywood to make a jig to compress the spring and remove split washers in my case, but some have a lock nut on the upper eye.  Once the spring is compressed back off the locknut and unscrew the upper eye.

[chewbacca5000]

Lets see the top.   I have wood clamps and used a holesaw and some plywood to make a jig to compress the spring and remove split washers in my case, but some have a lock nut on the upper eye.  Once the spring is compressed back off the locknut and unscrew the upper eye.

Thanks I will make up a similar jig and give it a go.  I think I have some plywood or scrap metal to make a jig.

[chewbacca5000]

Lets see the top.   I have wood clamps and used a holesaw and some plywood to make a jig to compress the spring and remove split washers in my case, but some have a lock nut on the upper eye.  Once the spring is compressed back off the locknut and unscrew the upper eye.

So far this looks the easiest.

https://www.youtube.com/watch?v=rpZyddxVARc

Thanks I will make up a similar jig and give it a go.  I think I have some plywood or scrap metal to make a jig.

[chewbacca5000]

Ok this weekend is the weekend all the parts are in wish me luck!

[chewbacca5000]

First thanks to Mcwilliams570 who totally hooked me up with a new top clamp and some much needed electric components.

Today was a battle and a half I had 3 sets of electrics for the CB500, but the sub harness I needed was a 73 and newer.  What I ended up having to do was take my terminal blocks and move them to a sub harness with bad terminals.  They were super brittle.  I was ready to give up until I read a post by two tired about using an exacto knife to remove the terminals.

Then while at advance auto getting contact cleaner I saw a jar of open wire ties and thought hey this might work, and sure enough it pressed the retainer pin for the terminal back in and made for easy removal.  Did it right there in the parts store and showed the guy behind the counter.

This was a hard fought victory now it is looking like I have electrics that stand a chance or working.  Hopefully I will get the carbs sorted out tomorrow.  Just keep finding more gunk.

[chewbacca5000]

So today I finally got the carbs rebuilt.  It really cool how many people have helped me on this project.  These are the carbs Greggo sent me which I combined with my own to make up a very sweet set of 627bs.  I think the carbs are worth more than what I have into this whole project. 

It was one heck of a puzzle trying to figure these out.  One thing I did right was I left the linkage alone and when I put it back together everything was just looking real good and my choke and other stuff did not need adjustment.

All set with floats at 22mm and air screws at 1 1/2 turns hope it is close enough to start.

Also finished up switching the 73 stator coil over to the 71 engine.  Had to do it since the plugs are different.  After that I think I broke the last rusty screw free and lubed up the cables for the carb install tomorrow.

Here is a pic of the finished product.

[Greggo]

Not bad considering I sent you a box of disassembled carbs

[Tews19]

Did you replace thw orings on the carbs? I need to get the orings for my 550. I dont want to buy complete kits when all I need are the orings

[chewbacca5000]

Not bad considering I sent you a box of disassembled carbs

Thanks it was alot of work these carb are a sun of a gun first time around.  I took my time and did not undo the whole rack just did one at a time.  The bodies of the ones you sent were much nicer than what I had so switched them all out.

 I learned my lesson from carbs past and left the linkage alone.

[chewbacca5000]

Did you replace thw orings on the carbs? I need to get the orings for my 550. I dont want to buy complete kits when all I need are the orings

I do have a right side float bowl I with the oil ring already glued in that I can send you.  I spent an hour using pliobond setting my carb orings.  Without this gas resistant contact cement you wil forever have headaches taking the bowls off.

Let me know this might be what you need.

[Frankensteins Bride]

Your making awesome progress!

[chewbacca5000]

Your making awesome progress!

Thanks Man!  Today it's adventures with powdercoat.  One tip for anyone doing this make sure you read the directions first.  I skipped that and used a whole mess of powder up on a battery box.  PSI was too high and the electrode was not out far enough pics to come latter.

Edit: attached a pic of the hotcoat gun notice how in the stock photo the electrode goes past the diffuser.  My came with the electrode not all the way through the diffuser.

That combined with too high PSI created a huge mess in the garage. 

[chewbacca5000]

Next pic is the brake stay that I powder coated starbond silver I am pretty happy with how it turned out considering this is only my second attempt.  The battery box was my first and you really can't see that anyway.

Really like this starbond silver has a nice texture to it.  I might even do my shock springs with this stuff it is that good.

I also got my tank and side covers sandblasted and ready for paint.  Last pic is the progress for the day.  Feels good with the big items done and over.

[Stev-o]

Looks good Chewy. Wish I had an area where I could p coat.

[chewbacca5000]

Looks good Chewy. Wish I had an area where I could p coat.

Yeah it's fun if you read the directions other wise it looks like this...

[chewbacca5000]

All you need is 5 to 8 PSI and a couple tablespoons of powder.  If you ever have any small bits send them to me and I'll bake them up for ya.  You just pay for powder and shipping. 

If I decide I really like it I will build a 4x4x6 oven. 

[Stev-o]

Looks good Chewy. Wish I had an area where I could p coat.

Yeah it's fun if you read the directions other wise it looks like this...

HA! Good one...

[chewbacca5000]

Looks good Chewy. Wish I had an area where I could p coat.

Yeah it's fun if you read the directions other wise it looks like this...

HA! Good one...

yeah I looked like a coal minner. 

[Mcwilliams570]

Looking good so far man. Glad the parts helped you out. Fire that baby up..

Matt

[BillGodRules]

Chewbacca,

Just saw your build.  Please let me know if you are in need of any parts. If I have it, it is yours. Looking good so far.

Just so you guys know I needed a couple of tappet covers and Chewbacca sent me ( and would not take anything for them.  Not even shipping.  I real standup guy that we all should help out if possible

You meet the nicest people on a Honda:)

[chewbacca5000]

Chewbacca,

Just saw your build.  Please let me know if you are in need of any parts. If I have it, it is yours. Looking good so far.

Just so you guys know I needed a couple of tappet covers and Chewbacca sent me ( and would not take anything for them.  Not even shipping.  I real standup guy that we all should help out if possible

You meet the nicest people on a Honda:)

Think I should be good just waiting on a CB500 clutch gasket cover.  If you have a spare I will gladly pay you for it.  Mine is comming from UK and might not get here until the end of the month.

My buddy really wants to get ridding.