Topic: '78 CB550k Carb Reassembly Problem

[bcollings]

So I've gone through and done a deep cleaning of my Keihin PD46C carbs on my '78 CB550k, but now that I'm reassembling the carb bank, I'm running into an issue.  I followed the rebuild guide written up by Brian Barnes (http://www.sohc4.net/cb550-faq/indexphp/pd46a-carb-rebuild-guide-by-brian-barnes), but this is written for PD46A carbs and does not seem to address my problem.  I followed his disassembly/reassembly instructions to the letter, but I'm still having this issue:

I have carbs 1 & 2 properly connected, and same with carbs 3 & 4.  Now I'm trying to connect the two sets of carbs by sliding the throttle shaft from carbs 3/4 into carbs 1/2, connecting the choke arms, etc.  However, when I am trying to slide the throttle actuator disk that is fixed on the throttle shaft over the choke actuator arm mounted on the side of carb 2, I can't seem to get it to clear (see photos).  I know that the choke actuator is supposed to be on the right of the throttle wheel, but I don't know how to get it through the throttle cable disk mount.  The furthest I can get it is where the last edge of the throttle actuator disk sits in the middle of the choke actuator arm (see photos).  I've tried all sorts of different combinations of twists and turns, along with moving the choke actuator/arm into different positions.  I was able to disassemble the carb bank without removing any other parts than I have on currently, so I'm wondering if there's anything else I need to remove/reconfigure to get them back together.  Anybody have any ideas?!

[harisuluv]

You put the throttle rod through with the other parts already in place.  If you put the cam on the rod then put the rest on you end up with it not fitting.

[bcollings]

So are you saying that I need to remove the throttle actuator disk, or the choke actuator (plus the choke arm?)?

[bcollings]

Got it, removed the throttle disk and it all comes together.  It's funny because I never had to do that to disassemble the carbs.  Thanks harisuluv!

[K3Owner]

Man, it's been a lot of years since I had this same problem but our resident carb builder has it right. IIRC, the throttle 'wheel' must be placed against the #2 carb and then the throttle rod slipped through it. Looks like a nut and allen screw will loosen the wheel. Those Honda engineers were all about precision.

You might hate the heavy spring so you can get a replacement spring at a good hardware store and stretch it to a clamp on the top end of the breather hose. Works like a charm. Also, after it's all together on the bike, doublecheck the choke action. Added stress from the installation can make it bind and result in no start. Happened to me. Loosening the top bras-like brackets and re-tightening straightened that out.

Good luck!

[bcollings]

Got everything back together over the weekend, and she runs!  I did hit a snag with the choke action (as K3Owner pointed out), but I added another turn to the light spring and kept the choke plates a little loose before tightening them down one at a time.  This had the choke snapping back in place just fine.  Thanks for the help!