Author Topic: 77 CB592 CR! (Read 13764 times)

Roar · « **Reply #50 on:** May 29, 2014, 05:00:56 PM »

Its time!

Ex port on cylinder 1 wet with oil, the others dry....

The carburetors I will leave alone for now, but the intake manifold will be matched to the top.

Valve tappets on intake side cyl. No 3 and 4 looks shot...

Camshaft out!

Top of!

Looks like it is running lean....? No surprise....

The chain tensioner works and looks ok....?

Looks like the piston rings has made some nasty marks in the cylinder walls....

Day 1 is over and the 550 is spread across my garage!

Stev-o · « **Reply #51 on:** May 29, 2014, 05:20:56 PM »

That was quick.

Roar · « **Reply #52 on:** May 30, 2014, 10:59:56 AM »

I took my time, but it went pretty smooth!

Today I took off the cylinders and took the head apart.

The pistonrings looked ok and were loose.

I used a little magnet to take of the valve retainers.

As you see the no. 1 ex valve is missing.... I cant get it out of the head, it is bent! The no.2 ex valve was bent slightly also, but I managed to get it out.

There is definetly room for improvement here!

550 cam clearence.....

650 cam clearence....

Cylinders from 1-4

To sum this up :
I have got two bent valves, 1 and 2 exhaustvalves. My guess is that the stiff valveseals became oval shaped, hence the blue smoke?
Cylinders are not looking good?... How do I know when to hone and when to bore?
The valves had a minimal play from side to side, is this normal or do I need new guides?.
Strange that it was not the tappets on the bent valves that got destroyed...?

iron_worker · « **Reply #53 on:** May 30, 2014, 01:03:40 PM »

What are the marks in the bore on #4? If those are pits then that bore is definitely no good.

I'm not sure how your compression was not apparently affected by your bent valves?!

Btw, what units are your compression measurements in? Seems like probably in Bar but the numbers seemed high for that. 13Bar = ~191Psi .... Are the pistons factory?

Anyway, nice work on the tear down and documenting.

IW

Roar · « **Reply #54 on:** May 30, 2014, 01:18:50 PM »

Thanks for the input, guys!

There is pitting on nr.4, I may have to bore....?
The valves was bent on the tappet side, so maybe they were sealing ok in the seat....? (i can not get nr 1 out of the guide)
Compressiontester, I am pretty sure it is in bar, but will double check asap.

I will try to find a micrometer to measure tolerances.

Stev-o · « **Reply #55 on:** May 31, 2014, 06:31:01 AM »

If the head cover is not installed properly, bent valves can occur. Wonder if that's how they were bent?

Roar · « **Reply #56 on:** May 31, 2014, 09:08:05 AM »

That was my thought also!
How do I get the valve out without destroying the guide?

Roar · « **Reply #57 on:** June 01, 2014, 08:36:36 AM »

I got it out, bent it to shape with a wise grip!

Roar · « **Reply #58 on:** June 03, 2014, 01:14:50 PM »

I am looking into buying a big bore kit, 592 or 605. Right now I an enquiering about a 605 kit, waiting for an update from the seller...

While I am waiting I am trying some porting!

Matching the intake!

Starting to fit snugly.

"Porting" wip!

Roar · « **Reply #59 on:** June 05, 2014, 12:33:47 AM »

Quote from: iron_worker on May 30, 2014, 01:03:40 PM

What are the marks in the bore on #4? If those are pits then that bore is definitely no good.

I'm not sure how your compression was not apparently affected by your bent valves?!

Btw, what units are your compression measurements in? Seems like probably in Bar but the numbers seemed high for that. 13Bar = ~191Psi .... Are the pistons factory?

Anyway, nice work on the tear down and documenting.

IW

Thanks!

The measurement were in bar for sure!

The pistons are factory Honda, yes.

iron_worker · « **Reply #60 on:** June 05, 2014, 08:25:41 AM »

The only reason I was wondering was that one value of 13 bar seemed high. Looking back though it looks like you only got this value with oil on 1 cylinder and the rest of your values are more like 10bar (~150 psi) which is more typical for these engines.

I've also bent a valve on the upper side of the guide (usually indicates the installer has done something silly ... IE myself). The machine shop had to cut my valve in half to get it out.

Fortunately the guides were fine.

IW

Roar · « **Reply #61 on:** June 12, 2014, 12:27:15 PM »

Ok!

I found a 592 kit(Henry Abe), with cylinders..... But the cylinder block was from a CB500!
The cylinder walls are pretty thin, and the OD of the sleeve is thinner than The CB550's. Was the sleeves in the H.A. kit of a smaller diameter than the standard 550? Or is this a case of overbored 500 standard cylinders?

My CB550 sleeves OD

The CB500 sleeves OD. Is this to thin or is this the sleeves from the H.A. Kit and ok?

Hope someone can help me? Thanks!

Roar

Roar · « **Reply #62 on:** June 13, 2014, 07:50:27 AM »

I just found out that these are indeed the sleeves from the "605" kit, so That is good!
I measured in the wrong place before, they actually measure 68,5mm OD.

The next thing I need is pins like these, are they avalible?

Thanks!

Roar

Tews19 · « **Reply #63 on:** June 13, 2014, 08:02:31 AM »

You can get the 120 piston kit off eBay. I have them and recently put the engine together this week.

Roar · « **Reply #64 on:** June 14, 2014, 08:11:00 AM »

Thanks for the tip, witch kit is that? I just find piston kits witch is 61,5mm...

Stev-o · « **Reply #65 on:** June 14, 2014, 08:49:51 AM »

Quote from: Roar on June 14, 2014, 08:11:00 AM

Thanks for the tip, witch kit is that? I just find piston kits witch is 61,5mm...

Here is the kit Tews is referring to. The seller is based in Japan...

http://www.ebay.com/itm/Honda-CB550F-CB550K-600cc-Bigbore-Piston-Kits-with-Head-Gasket-CB550FBB-/161127970617?pt=Motorcycles_Parts_Accessories&hash=item2583f9b739

Harald F · « **Reply #66 on:** June 27, 2014, 06:27:39 PM »

får nesten følge dette prosjektet:D fin sykkel.

Tews19 · « **Reply #67 on:** June 29, 2014, 05:31:49 PM »

Yep, Stev-o has the right link. Hopefully I will be getting the engine running before summer ends

Roar · « **Reply #68 on:** July 02, 2014, 04:08:39 PM »

I just found out that the wristpins I need are the same as CB900 dohc, so they are on the way along with new clips!
Here I have modded the piston to take the 3 piece oilring from the CB750.