Author Topic: 1975 CB550 Winter 2013 Build (Read 23815 times)

Chaser60 · « **Reply #75 on:** May 22, 2014, 09:10:10 AM »

Also re-installed battery box and test fit the ebay used 4 into 2 header I purchased. No idea who produced these. Really hard to find a 4 into 2 system. These go cylinders 1-4 to the left side of bike and 2-3 to the right. They had these nasty little chrome cocktail shaker style mufflers that I will not be using. Anxiously awaiting twins from Cone Engineeging ! Will decide if they are going straight out the back or will angle up. At moment, leaning angle up but will see once I have hardware in hand.

Headers were more rusted and blued than I thought from the pics, so they are off to be ceramic coated.

Had originally planned to have this bike back on road by end of May. Will finish rest of build over this 3 day holiday weekend and hopefully only be waiting on exhaust.

Chaser60 · « **Reply #76 on:** May 22, 2014, 09:22:36 AM »

Last post for today and actually backing up several steps in the build. The seasoned vets here will all know this, but for the less informed (like me) here were my learnings about removing and installing the top cover.

Remove the tac cable housing / tac gear housing. Small housing that bolts onto cover. A simple step that will keep you from buggering the gears on reinstallation.

Back off all the clearance adjusters fully. You will be re-setting them anyways, and failure to do so just means that at least one of them is fully engaged and under tension so when you unscrew and unbolt the cover, it will sort of hang up on the 2 guide pins unless you are just lucky on cam lob position.

This rubber band trick is well discussed and simple. Oh and it works flawlessly. If you dont know why you care about this. Check the manual. There a pictures and bad things happen if there is misalignment during install.

Chaser60 · « **Reply #77 on:** May 22, 2014, 09:25:22 AM »

Thanks goldarrow. Sadly this is my only SOHC at this moment. From your signature, I think it is I that am jealous. These things are great fun to build and ride. I have way overspent my budget, but overall, I am still smiling every moment I am in the shop. And hope to be outright laughing out loud on the road soon.

Thanks again for your help with the airbox parts.

riverfever · « **Reply #78 on:** May 24, 2014, 08:16:17 PM »

Everything looks great.

riverfever · « **Reply #79 on:** May 25, 2014, 08:44:22 AM »

Hey I was checking out this thread and it looks like Scott S has the same petcock. Shocker but...his sock filter was also destroyed and he replaced it with an extra that he had. I bet he can take a closer look at the holes you were asking about in the trashed one. Check it out. Scroll down.

http://forums.sohc4.net/index.php?topic=126113.25

Chaser60 · « **Reply #80 on:** May 25, 2014, 04:44:33 PM »

Spent most of today trying to get this closer to done. Waiting on exhaust and a shipment of small things (like the tac housing gasket) so today was really a day to focus on the last details

Clutch cable

and throttle cables installed. Didnt get a pic of these, but they run down through gage mount hole in center of triple tree and then along left side of frame under the tank.

Next up put on the new grips. This was a first time. Used hair spray. Will wait to see how it dries.

.

One thing to note. On these 400f bars, the position of the clutch lever and the bar end mirror will slightly interfer. I was done for the day by time i discovered this so will either reposition mirror, cut the ball off the clutch handle or find a clutch handle that is about 1/2 inch shorter.

Chaser60 · « **Reply #81 on:** May 25, 2014, 04:48:58 PM »

painted and polished the last cover. Basically same process as before. Sanded, then polished. For the paint, I used small bottle of Testors model laquer and a brush. Was ok to be sloppy on the letter tops because once dried, just put a little 600 on a block of wood and run it across the letters flat side and it comes out pretty clean

Chaser60 · « **Reply #82 on:** May 25, 2014, 04:59:10 PM »

The last mile is always the longest. A dozen little side projects.

Rebuilt the petcock. Got some help from riverfever on that. Seems the 75 and 76 CB550 had a bit of a bastard child petcock. I basically stood in front of a bunch of o-rings until i found a few that seemed close. tested it with water. It didnt leak. took it back apart and dried before installing on tank. Also stripped off the filter materials as it was torn and had holes.

Rebuilt and reinstalled the gas cap also. Had some help from johnie and riverfever on this too

wasnt sure how the gasket installed, but these folks helped me out

the answer is: The gasket captures both plates. Thick side down. Really a nice drawing by the way. Make sure your vent on the picture is clear. You should be able to blow through it with minimal resistance once the gasket is in place.

Chaser60 · « **Reply #83 on:** May 25, 2014, 05:11:34 PM »

Added in line gas filters. Well actually only did half the job. Need to find one that has a 90 degree outlet so that will wait until next week. Just cant fit them in with out a kink in the hose or an uphill flow. I have seen these in town, so will handle that next week.

In mean time installed tank, seat, headlamp and bar end mirrors. Getting there. A few things to finalize tomorrow and then just waiting on UPS and the exhaust header ceramic coating. Need to work out a bracket for the mufflers and that will take some welding so probably 2 weeks from starting this up.

Front view

Right side

top side

left side

back side

Headed for finish line and that fateful moment of cranking the engine for first time. Cant wait. For those that have helped me on this build thread and my other questions on the main board...thanks again.

Stev-o · « **Reply #84 on:** May 25, 2014, 06:02:25 PM »

Not sure how I missed this til today? This bike is turning out sweet!

goldarrow · « **Reply #85 on:** May 25, 2014, 06:04:39 PM »

Quote from: Stev-o on May 25, 2014, 06:02:25 PM

Not sure how I missed this til today? This bike is turning out sweet!

Too much attention poured into the patina bike?!

frankist · « **Reply #86 on:** May 25, 2014, 07:00:08 PM »

Is your master link(clip style) on backwards? its hard to see in the picture but I think its suppose to be on the other way. Unless Im wrong. Awesome progress by the way!

goldarrow · « **Reply #87 on:** May 25, 2014, 07:30:14 PM »

Quote from: frankist on May 25, 2014, 07:00:08 PM

Is your master link(clip style) on backwards? its hard to see in the picture but I think its suppose to be on the other way. Unless Im wrong. Awesome progress by the way!

Nice catch. I would turn it the other direction

Chaser60 · « **Reply #88 on:** May 26, 2014, 03:05:06 PM »

Thanks all for the encouraging words. I have no idea how you saw that master clip from these dark photo's ...Whats' worse is that I didn't know it mattered. Will flip it around, easy enough to do. Thanks again.

Chaser60 · « **Reply #89 on:** May 26, 2014, 03:06:56 PM »

regarding master link clip, should opening be facing front or back when link is on bottom side of sprockets?

goldarrow · « **Reply #90 on:** May 26, 2014, 04:27:18 PM »

Quote from: Chaser60 on May 26, 2014, 03:06:56 PM

regarding master link clip, should opening be facing front or back when link is on bottom side of sprockets?

Flip it the other way. Should make sense as you turn the wheel or direction of travel...

(Read-I don't know how to describe it)

Tews19 · « **Reply #91 on:** May 26, 2014, 05:13:35 PM »

Nice build and the paint came out absolutely gorgeous!

SOHC4 Cafe Racer Fan · « **Reply #92 on:** May 26, 2014, 05:35:55 PM »

Looks like this one's almost a wrap! That or the name of the thread will have to change!

Chaser60 · « **Reply #93 on:** May 30, 2014, 10:38:29 AM »

The CONE brothers have arrived. And they are identical twins ! Can not wait to hear them sing.

First thing they needed is to have a small bracket welded on both for my attach points at the rear peg area. I have zero welding equipment or skills, but found a local guy that would do it while I waited. Cary rides a great old Harley that he showed me pics of. A great vintage ride that he has done some very nice work on.

I also picked up the 4 into 2 used aftermarket headers from ceramic coating yesterday. I didnt snap a picture, but they look great in a nice matte black.

I think I now have all the bits and pieces to take a hard run at finishing this up over this weekend and arriving at that anticipated first try to crank it up....and the much more anticipated first ride since the beginning of November.

Chaser60 · « **Reply #94 on:** June 01, 2014, 12:23:09 PM »

Headers mounted today.

Love the matte black of the ceramic coat. overall easy install.

Chaser60 · « **Reply #95 on:** June 01, 2014, 12:31:46 PM »

Next up the cone engineering quiet core mufflers and mid pipes. All they had is single 18 degree mandrel bends so that is what I am working with for the mid pipe. Basically job was mount headers without the new crush washers to mock up the layout. Measure 3 times to be sure I didnt mess up. Trim the headers at the collector. Trim a bit off each end of the mid pipe, 5/8 inch long slots at end of the muffler and mid pipe where those go over another pipe. This was recommended by Cone so that the clamp could draw in the joint. Used a dremel and made 4 slots 5/8 of inch long 90 degrees apart. Picked this length so it would be fully hidden by the clamp.

Clearance all around is good. Here is a side view

and one from the back too

Next up, need to go out and buy a little metal to fab the bracket that will run from the rear peg set down to the bracket that was welded onto the mufflers a few days ago.

This bike was going to hit the road today, but I have hit a major snag with the carbs. Will post that in next part.

Chaser60 · « **Reply #96 on:** June 01, 2014, 12:41:56 PM »

I could really use some advice on this issue. It is also posted on the other Q&A part of the forum, but have had limited replies.

I have run into a problem with the throttle. All this is done with engine off. Bike is not running. When I twist the throttle grip and just before WOT, I feel a catch. Then it does not return to closed without assistance. I can hear a noise and then once i trwist closed past the catch point it returns to closed without further assistance. I have a short video from my iphone (.mov format) that shows the carbs for 1 and 2 cyl. If you look closely you can see that the #2 actually move up(open) slightly more than number one. There is also a little loose play in the number 2. Meaning if I push on the brass colored nut on number one there is almost no wiggle or play. If I do same on #2, I can move it up and down slightly.

I disconnected the throttle cables. The throttle grip and cables work very smoothly so the issue is in the carb throttle mechanism or internal (oh man, I hope not internal....)

So if I operate the throttle cam by hand, I still get the same "hitch" or catch or binding. It really seems like it is happening somewhere between #1 and #2 carbs. It is so strong that the return spring can not immediately return to closed. With a little assistance or just time, it will push through the catch and back to closed.

Any ideas on cause or suggestions how to trouble shoot this further. I am dreading pulling carbs back off this bike as I was so damn close to hooking up gas and giving it a try, but this is not safe as it is.

attaching vidoe again. This was taken when the throttle cables were attached, but same issue happens without cables attached. It is just wicked hard to open the throttle due to the spring force.

Ok, so I dont seem to be able to embed the video. So first question is how do I attach or post a .mov file?

http://youtu.be/eaBkxvjfh_0

SOHC4 Cafe Racer Fan · « **Reply #97 on:** June 02, 2014, 12:39:06 AM »

Like the look of those Cone Engineering mufflers on the 4-2 headers.

goldarrow · « **Reply #98 on:** June 06, 2014, 11:06:43 PM »

Check and try to adjust correctly the throttle stop screw on the carbs. And see if that catching is still there

onetruepunk87 · « **Reply #99 on:** June 08, 2014, 06:31:24 AM »

Just read through your whole thread, the bike looks amazing, can't wait to see it finished! I wish I had the same header pipes to copy that exhaust on my 500.

I saw earlier on you were looking for smaller reflectors, have you looked into the 71' CB500 reflectors (CB500 K0). They were smaller in diameter than the other years and would probably swap right into a 550.

I'm not sure how similar the 500 and 550 carbs are, but in relation to yours getting caught up, when I was putting my 500 carbs back together last month I was checking to make sure the slides were all moving freely before I folded up the "tongued washers" and one was getting caught up not letting it close all the way without force because I hadn't bent it back yet. I know you said you didn't go into the carbs but it's easy enought to unscrew the carb tops and check the previous owner's work.

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Author Topic: 1975 CB550 Winter 2013 Build (Read 23815 times)