Topic: Two 550's and a 500. Home stretch now

[2strokeTrush]

   Hey guys, I had another thread going about this 500 but it seemed to loose interest, so I decided to start another one that included the new plans to build one bike out of three since the original one had so many issues.....A little backstory first though.



    I bought this 1971 Cb500 back in March for 300$ non running,  I got her going only to soon realize she had the very dreaded 500 clutch issue.  After many attempts to fix this and adding and cleaning parts I called it quits on the engine in hopes to find a 550 soon.  Well as luck would have it I got in touch with a guy who has two 550s he is trying to part with cheap.  One complete and one parts bike.  I will be picking them up soon and then decide whether to build on the complete 550 platform or swap a 550 motor. I have a little shop in the basement of my parents old house, so I do have a good workplace.  I have not rebuilt a engine before, so I will need help in the engine rebuild area big time. 

My Basement Shop...


The 500 and my little 350f...


The 500 is so good looking besides the engine, Im pretty sure a 550 swap will be in order.  Use parts from both new bikes and the better of the two engines.  Considering building another bike out of what parts are left but that will come later! Few more pics of the 500 right now.  As soon as I pick up the two 550's Ill post pictures!







Fast Forward to today, Engine is out and took forever! I took off the oil pan to ease the pain in pulling the motor,  can you tell its my first time yet??  I plan to use the old 500 motor as a practice engine, teaching myself to lap valves and adjust things as needed, and use what parts I can. 

[grcamna2]

Good for you Tyler ! I look forward to seeing those 550's and I'll enjoy being part of your New project(s)  Watch out for working on 3 bikes at a time,it'll wear you out quick ! I've done a few jobs where I made a deal/contract w/ a guy to build his bike from a parts bike & I figure I worked at least twice as many hrs. doing it that way...

[2strokeTrush]

Good for you Tyler ! I look forward to seeing those 550's and I'll enjoy being part of your New project(s)  Watch out for working on 3 bikes at a time,it'll wear you out quick ! I've done a few jobs where I made a deal/contract w/ a guy to build his bike from a parts bike & I figure I worked at least twice as many hrs. doing it that way...

Yeah its defiantly going to be a new experience! Thank you for all your help on the other thread by the way, really wouldn't do all this without you guys!

[Tews19]

Great looking bikes! I'm curious if you are keeping the side covers?

[Trad]

Nice base. Looking forward to seeing the two 550's.

[2strokeTrush]

Great looking bikes! I'm curious if you are keeping the side covers?

Thanks man, yup Ill be keeping them as the tank is much nicer on the 500 then either of the 550's so Ill most likely run the 500 side covers as well.

Nice base. Looking forward to seeing the two 550's.
[/quote

Thanks! Hoping this will come together nicely.  Im hoping to have the 550's next week so ill be sure post them!

[2strokeTrush]

Pulled the wheels and brought the bike down to the shop today, makes it much easier to carry down the steps with no wheels.







Also as Im wanting to teach myself how to rebuild engines I started on the teardown and removed the top end cover.  Pretty simple besides some seized bolts...







First Newbie Question here, but what are the next steps to remove the Jugs to view the Cylinders and Pistons??

[calj737]

A few things: always loosen the adjuster nuts on top of the valves before removing the cover. This prevents you from bending a valve as the rocker arms are attached to the cover...

To remove head and separate from jugs:
Loosen the cam chain (10mm nut on rear of engine, below intake ports)
Cam chain sprocket has 2 nuts, loosen them each, allowing cam and chain to separate with just enough slack to remove cam from head by sliding it out. (Caution: restrict the chain from dropping into the engine with a bungee or something)
Once cam is out, proceed to remove all the head bolts, preferably using the correct pattern.
Wriggle and jiggle the head free. This may be "stuck" after some years, but take your time, be creative, and DONT whack it or pry it with metal chisels.
Set head aside carefully, and collect all nuts, washers, pucks, and dowels.
Jugs are now "free" but may be semi "stuck" to base gasket. Same technique as above. I drip some light oil or spray WD into cylinders and rotate crank via alternator bolt as I remove jugs to help shove the cylinders up and away from lower case.

All done.

[2strokeTrush]

A few things: always loosen the adjuster nuts on top of the valves before removing the cover. This prevents you from bending a valve as the rocker arms are attached to the cover...

To remove head and separate from jugs:
Loosen the cam chain (10mm nut on rear of engine, below intake ports)
Cam chain sprocket has 2 nuts, loosen them each, allowing cam and chain to separate with just enough slack to remove cam from head by sliding it out. (Caution: restrict the chain from dropping into the engine with a bungee or something)
Once cam is out, proceed to remove all the head bolts, preferably using the correct pattern.
Wriggle and jiggle the head free. This may be "stuck" after some years, but take your time, be creative, and DONT whack it or pry it with metal chisels.
Set head aside carefully, and collect all nuts, washers, pucks, and dowels.
Jugs are now "free" but may be semi "stuck" to base gasket. Same technique as above. I drip some light oil or spray WD into cylinders and rotate crank via alternator bolt as I remove jugs to help shove the cylinders up and away from lower case.

All done.

Your the man! Thank you for that Sir!

[2strokeTrush]

No real updates yet guys, I had a little vacation time I needed to get rid of before school starts, so I spent some on the beautiful shores of The Chesapeake Bay!  Good news is I talked to the guy with the 550's today and we set up a time for me to come get them next week!  He also said he has one more he wants me to look at, but it all depends on money!  Even better news is he says he has a 1981 Kawasaki KL250 With title that I can have for free!  Don't know anything about them, but its gotta be worth something! Cant wait!

[2strokeTrush]

   FINALLY got to start this off right!  Got ahold of one of the 550's.  The other one should show up within the next two weeks.  Apparently there was some confusing of where the owners father had moved the bike, but he figured it out so hopefully next week I can go pick it up!  This may get confusing, but I'll try to keep it simple!

  This one is a 1973 titled as a 74, I guess it was a leftover.  Anyway its complete and a little rusty.  Original seat which I really like, its much thinner then my 500 or 350 and I really like the look.  Even had the owners manual underneath! No tool kit though:(  Tank was rusty on the inside, and one small dent on the side, but the paint is actually alright.  I threw fresh gas and the clean 500 tank on her to try and get her to start.  Half decent 4into1 with plenty of rust, but remember I have the 500's Trumpet's to throw on. Also has the little turn signal alarm under the dash. Front brake pads were locked up on the rotor, but I managed to free them.  I put some oil on the cylinders, adjusted the points, fresh gas and a battery and she started!  Blew a little smoke and rust particles from the pipe, but otherwise its pretty decent.















     The bike shows 23,000 Miles, but the gauges don't match.  Anyway to tell which is original if any?  Parts of the engine mostly the clutch and sprocket cover have started to fade away into some sort of dusty scratchy stuff.  Anyone think that could be polished? I Have decided this bike is to complete to pull the engine and swap it to the 500.  The owner says the other 550 has a very good engine, but the bike itself isn't much.  So that will be the donor engine bike.  That is a 77 or 78. Good year? 

   SOOOO this one will go down in the shop the same way the 350 did, with the wheels and exhaust off, then reassemble down in the shop after it gets down the few stairs and a turn.  I took the seat, tank, carbs, exhaust and fenders off for now so its lighter on the way down.  The other 550 Ill most likely strip the engine outside and take it down just like the 500. Sorry about the crappy pics.









And this is the bike the owner gave me for free with the sale.  Not sure what Ill do with it, but its got a title and is pretty cool.  Its  Kawasaki Kl250.

[Tews19]

I have a feeling the exhaust on the purple 550 will clean up well with some steel wool 000

[2strokeTrush]

I have a feeling the exhaust on the purple 550 will clean up well with some steel wool 000

Yup me to, loose fine rust, but I'm not crazy about the 4into1.  I think it takes away allot of the look from the front of the engine.

[Tews19]

I'm a fan of a stocker but 4-1 on the 550 just screams. Sometimes it looks good to be differently!   

[2strokeTrush]

I'm a fan of a stocker but 4-1 on the 550 just screams. Sometimes it looks good to be differently!   

Hahaha good point!  So what do you think of this platform? 

[grcamna2]

I'm a fan of a stocker but 4-1 on the 550 just screams. Sometimes it looks good to be differently!   

Hahaha good point!  So what do you think of this platform?

Tyler, By "platform" do you mean the purple 550 ? I like it ! Does it have a title ?
I hope your 350 is running mint so when you need a break after all this work of restoring many bikes at once you can enjoy the ride 

[Tews19]

The white flaky stuff is usual corrosion when left out in the elements. I would think it should come off. Seems like you are more in favor of a stocker bike as a platform. Is that what you meant?

[SohRon]

This one is a 1973 titled as a 74

The '74 models were built from July '73 to June '74, so you (apparently) have a '74 K0 there. Good looking CB500... good luck with the swap!

[Trad]

Nice scores! Keeping my eye on this thread. 

[goldarrow]

650 camshaft swap is a nice addition to the mid range power

[2strokeTrush]

I'm a fan of a stocker but 4-1 on the 550 just screams. Sometimes it looks good to be differently!   

Hahaha good point!  So what do you think of this platform?

Tyler, By "platform" do you mean the purple 550 ? I like it ! Does it have a title ?
I hope your 350 is running mint so when you need a break after all this work of restoring many bikes at once you can enjoy the ride 

Yep the Purple one,  It should fit nicely here in Baltimore, purple being our team colors!!  And actually I think I will keep the 500 transplanted  with the 550 motor as a MOSTLY stock cruiser, for longer trips.  The purple 550 seen above I am considering making a Full Out Cafe Racer. Remember I still have one more 550 to pickup-The engine from that will be going in the 500.  Basically after I swap a 550 in the 500 it is a pretty decent stock cruiser, wouldn't think it needs to much more, since its pretty cherry to begin with.  I told you all this would get confusing!!

This one is a 1973 titled as a 74

The '74 models were built from July '73 to June '74, so you (apparently) have a '74 K0 there. Good looking CB500... good luck with the swap!

Thanks for the info!  I don't think I need to say how amazing your build is, That thread speaks for itself!

650 camshaft swap is a nice addition to the mid range power

I was considering this for the Cafe I have in mind, how hard is that?

[goldarrow]

Camshaft swap is as difficult as just drop it in, check for clearance then button up

[2strokeTrush]

Camshaft swap is as difficult as just drop it in, check for clearance then button up

Hmmmmmmmm

[calj737]

Camshaft swap is as difficult as just drop it in, check for clearance then button up

Well, sort of like that. There's a few other steps, like swapping the cam chain onto the new cam, timing the engine, and of course, the tach gear must be changed (your gauge too) as the 550/650 are different.

It is a pretty easy swap, but there are a few gotchas to be aware of.

[2strokeTrush]

Camshaft swap is as difficult as just drop it in, check for clearance then button up

Well, sort of like that. There's a few other steps, like swapping the cam chain onto the new cam, timing the engine, and of course, the tach gear must be changed (your gauge too) as the 550/650 are different.

It is a pretty easy swap, but there are a few gotchas to be aware of.

Thanks Cal, Good to know!  Theres lots to do before I would even think of swapping a cam yet, but I'm glad its been done and people here know the dos and donts!