Topic: CB 500 Four (1972?) Full Restoration

[bryanj]

What was the problem mate?

[MickB]

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]

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]

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]

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]

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]

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]

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.

[calj737]

That brake piston seal groove is beautiful, Mick. Assemble that thing already!

[MickB]

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

[bryanj]

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

[MickB]

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

[MickB]

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]

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]

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]

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

[MickB]

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

[calj737]

Mick - you might try a trick on that pivot pin before reassembling. Check about to see if you can locate a specialist coatings company to apply a Dry Film Lubricant coating to it. Prevents any corrosion and maintains a far better operation longer than jamming it full of grease. It's a baked on finish much like powder coat and impregnates the surface of the pin. Nice and slippery- and no mess!

[Tews19]

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.

[MickB]

Cleaning skills extraordinaire - elbow grease

[Tews19]

Cleaning skills extraordinaire - elbow grease

Popeye arms I bet.

[MickB]

Thanks Cal I'll look into what you're suggesting. Does it need to be baked on professionally?

[calj737]

Yes, DFL is a specialized coating and I've not seen it available as a DIY.

Polishing skills: I've had decent success with Petroleum Jelly as a rust solvent. Apply, wrap under cellophane, wait, wipe away. Occupy waiting time with a cold, frothy friend 

[MickB]

Cal you're a never ending source of ideas and time wasters. Keep 'em coming.

[MickB]

Cal is it late or early where you are? I'm surprised getting notes from you at this time of the night here in Sydney.