Author Topic: CB 500 Four (1972?) Full Restoration (Read 145118 times)

Bootsey · « **Reply #250 on:** August 28, 2014, 01:59:34 AM »

This is from a 550, but I imagine they are the same. The bearing you can see is the one that the primary shaft goes into on the left hand side. You can see that plate and screw in front. Hope it helps

MickB · « **Reply #251 on:** August 28, 2014, 04:39:11 PM »

Thanks Bootsy

MickB · « **Reply #252 on:** August 29, 2014, 02:58:23 AM »

Got a bit done today,

After realizing Oil Guide "A" wasn't put in place (it's not clear in the schematic where it's to go) before I put the primary crank shafts in I used 2 magnets, 1 to hold it I place and the other a magnetized Philips head screwdriver I got in first go (it's now in the place where it should be.

Still have to fix up the kick starter and tomorrow I hope to put the cases together, with a bit of luck.

Bootsy was a big help today with answers to questions , as I didn't tear the engine down so I have no reference.

Is there anywhere (I can't find it) where it shows (with photos) a CB500 engine being rebuilt? The manuals are ok sort of but when you didn't put it apart it's really difficult.

MickB · « **Reply #253 on:** August 29, 2014, 10:38:38 PM »

Can anyone help as I'm having troubles getting the gearbox in and working

Is the drum shift in correctly, I can't get the front shaft to drop in place as the rear selector forks are hitting on the front shaft cogs?

Have I been sent to Coventry?

I can't find a post that covers this off, gearbox installation.

The shafts are in the upper case for ease (haha) of installation.

Is the drum shift in correctly?

Spins fine at present

See the position of the shift drum now

I can't get the front shaft to drop down into position.

Forks are hitting the cogs on the front shaft.

bryanj · « **Reply #254 on:** August 30, 2014, 03:50:39 PM »

Might sound daft but have you got the gears on the correct shafts in the right order and orientation---been there got the T shirt

MickB · « **Reply #255 on:** August 31, 2014, 12:14:00 PM »

Bryan thanks for your reply.
I think I've got the gears on the correct shaft and in the correct order including the washers, but I'll double check.
I think the problem is in the shift drum, I've got it not in the correct way, either I'm 90 degrees out or something like that.

MickB · « **Reply #256 on:** August 31, 2014, 08:22:11 PM »

Had a win - found the part I was missing for the engine - tachometer drive

MickB · « **Reply #257 on:** September 01, 2014, 11:51:45 AM »

Got the gearbox and shift drum in and working.

bryanj · « **Reply #258 on:** September 02, 2014, 12:17:51 AM »

What was the problem mate?

MickB · « **Reply #259 on:** September 02, 2014, 01:48:25 AM »

Bryan I felt it was a combination of 2 errors I'd made and I couldn't find an answer to either on the SOHC Forum.
1st the drum stop cam, I had the plate set incorrectly, I'd reinstalled the longest pins into the wrong hole and all the other pins were then wrong also.
2nd the selector forks were installed with the left fork on the right side and visa versa. I had mixed up the orientation as I was installing the Shift Drum upside down in the upper engine case.
Basically a newbie error, never having worked on a CB500, next time I won't make that mistake again, probably a different mistake.
As soon as I corrected the Shift Drum Cam and fixed the Selector Forks it just all fell together.

The key learning I believe was to walk away from it (I left it for 48 hours and polished some cases and bolts), then come back and you see things clearer rather than seeing through frustrated eyes and not being able to see past your mistake.

I trust I've explained it well enough so you can understand.

bryanj · « **Reply #260 on:** September 02, 2014, 08:24:50 PM »

It's called the McGinty factor mate----If something can be fitted the wrong way round somebody somewhere will do it, they say it is one reason for the vast difference in vane size at each end of a jet

MickB · « **Reply #261 on:** September 05, 2014, 03:25:08 PM »

Found a brand new 4 into 2 exhaust for $200! Snapped it straight up. I wanted an original exhaust but $3000 from CSMNL is too rich for me.

I've never been real keen on the 4 into 1 systems, I know that'll create a storm wIth some of the members.

I found on SOHC (don't know where, I can't find it now) a bike with Norton Whistler mufflers on a 4 into 2 and thought it was a really nice look on the CB, it was a beautifully balanced look with the 2 mufflers.

Next look on eBay.

MickB · « **Reply #262 on:** September 06, 2014, 03:27:43 AM »

Went through all nuts, bolts and washers - off to get new zinc plating. It means I can't put anything together so time to get polishing and cleaning.
Finish carbies and get onto some painting.

Cleaned up brake caliper

Got the side stand onto the frame - thanks Oddjob, your tip on SohRon's build. If it looks odd it's because the frame is upside down at present. I remembered what SohRon did he installed a spring washer on the side stand holding bolt, I included a spring washer also, thanks SohRon.

bryanj · « **Reply #263 on:** September 07, 2014, 10:45:56 PM »

The seal groove in that caliper looks like it still has some kack (technical term) in it---needs to be as spottless as the rest mate along with a new seal

MickB · « **Reply #264 on:** September 07, 2014, 11:07:27 PM »

Thanks Bryan, maybe the photo shows dirty, but when I look it's pretty clean. I used a Dremel wire wheel. Any suggestions on how to do a better job? I'm unsure how to do it better.

MickB · « **Reply #265 on:** September 08, 2014, 03:02:49 AM »

Bryan here's some photos of the caliper, I did get rid of a couple of paint spots I'd missed, also I think the better lighting shows it up. The recess looks ok to me, let me know what you think

Also, I cleaned up the advance mechanism, I took photos of it prior to dismantling and put it back as the first photo. Note the notch at the top of the advance, i replaced exactly as it was. Please advise if it's incorrect.

MickB · « **Reply #266 on:** September 08, 2014, 04:30:59 AM »

Cal nice to hear from you again, it's been so long.
Thanks for giving it the thumbs up.

bryanj · « **Reply #267 on:** September 08, 2014, 11:41:12 PM »

The dark ring must be a shadow, clean the pivot pin to the same standard and that brake will be better than new!!

MickB · « **Reply #268 on:** September 08, 2014, 11:58:34 PM »

Hey Bryan, what do you mean by the "pivot pin"? Do you mean the holding pin?

MickB · « **Reply #269 on:** September 09, 2014, 03:08:12 AM »

The grommets for the side covers arrived today, 4 large and 2 small.
Can someone advise me which way the grommet faces, as they have differing sides to the grommets.

Bootsey · « **Reply #270 on:** September 09, 2014, 11:38:45 PM »

Hey Mick. From what I've seen on my frame, the grommets push in from the outside, larger face pointing outwards.
Just a thought with the advancer, I can't quite see it in the photos, but might pay to double check the notch in the barrel is lined up with the hole in the plate. Check out this post, down towards the bottom, you'll see a post by Dave, with pictures showing what I mean.
http://forums.sohc4.net/index.php?topic=140288.0;topicseen

MickB · « **Reply #271 on:** September 10, 2014, 12:45:51 AM »

Thanks Bootsey for your assistance, answer and link to the advance mechanism. I replaced each part exactly where it came from, if you look on top of the barrel you'll see the notch on mine but not present on the pictures. But I'll read up and double check, thanks.
Picked up the 4 into 2 ($200) exhaust today. It was pretty dirty, bucket of hot soapy water, nylon scourer (got most of the tiny pitting), tea towel for drying and then chrome polish. It came up pretty well. It still needs more of the scourer as there are plenty of tiny pits, it'll do until I get it going, no idea what the chromer would charge (probably like a wounded bull).

Before cleaning

After cleaning

Still lots of parts to restore, dropped all the nuts and bolts in for re-zinc - 2 weeks wait.
So the plan is to first finalise the seat restoration with Chaser's foam, then polishing and painting with POR15 glisten on the alloy covers, true front and back rims and balance tyres.

I can start to see the end of the resto.

bryanj · « **Reply #272 on:** September 10, 2014, 12:48:52 AM »

Pivot pin is the one that the alloy bracket the caliper bolts onto swings on

MickB · « **Reply #273 on:** September 10, 2014, 12:49:52 AM »

Thanks Bryan I've got it ready to go straight on the fork.

Tews19 · « **Reply #274 on:** September 10, 2014, 04:38:15 AM »

Quote from: MickB on September 10, 2014, 12:45:51 AM

Thanks Bootsey for your assistance, answer and link to the advance mechanism. I replaced each part exactly where it came from, if you look on top of the barrel you'll see the notch on mine but not present on the pictures. But I'll read up and double check, thanks.
Picked up the 4 into 2 ($200) exhaust today. It was pretty dirty, bucket of hot soapy water, nylon scourer (got most of the tiny pitting), tea towel for drying and then chrome polish. It came up pretty well. It still needs more of the scourer as there are plenty of tiny pits, it'll do until I get it going, no idea what the chromer would charge (probably like a wounded bull).

Before cleaning

After cleaning

Still lots of parts to restore, dropped all the nuts and bolts in for re-zinc - 2 weeks wait.
So the plan is to first finalise the seat restoration with Chaser's foam, then polishing and painting with POR15 glisten on the alloy covers, true front and back rims and balance tyres.

I can start to see the end of the resto.

Wow! Very impressive cleaning skills! I like the bend of the pipe to the muffler. Usually the 4-2s I've seen are straight. Looking forward to seeing those mounted up.

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Author Topic: CB 500 Four (1972?) Full Restoration (Read 145118 times)