Topic: Patina Hyena - 550/650 674cc Hybrid Cafe Build

[dave500]

the cam bearing journals look ok,so do the lobes.

[DaveBarbier]

the cam bearing journals look ok,so do the lobes.

Great, haha. That saves me a lot. Even though on one of the journals I feel texture/maybe scratches with my nail?


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1978 Honda CB550K

[Bootsey]

The manual says to remove the rotor with a puller. I've been reading I can use a longer nut of the same size/thread pitch. But do I really need to remove this? It looks like the cases will separate without this coming off. I'm saying this because this nut is really hard to get off. I wish I had an air or electric impact gun. All I have are hand tools, beer and PB blaster.


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1978 Honda CB550K

You are correct, you can separate the cases with rotor on.  If you want to change the main seals, you need to take it off though. If you can hold the crank from spinning, you can put a socket and bar on the bolt shown in the picture, and rap the bar, with a rubber mallet to get that bolt out.
Then to get the rotor off, grab yourself a M16 x 1.5 bolt, and a rubber mallet, tighten the bolt, give it a rap with the hammer. Repeat, and the rotor will just pop off.

[DaveBarbier]

Thanks Bootsey, not sure if I want to change the main seals. Don't know if that came with my gasket set. Maybe I'll cross that road later.

In the mean time, I broke one screw on the clutch cover and had to drill another out. Super stripped. The cover is/was almost impossible to remove. Looked all over the forum and tried all that a stuff. So instead I just tapped one of the cover holes with an M8 1.25 tap and threaded in a bolt. As I tighten it the cover is slowly being pulled off (but first in the hole I put a long nail so the bolt has something to push off of.) Seems to work very well.


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1978 Honda CB550K

[Bootsey]

Nice idea with the cover. I had a bit of trouble getting my clutch cover off too, it was pretty baked on there. Took a fair bit of persuasion from the rubber mallet.

Seals don't cost too much, might be worth it, if you cracking the cases anyway. You can buy them individually, or get a kit like this. You can probably find it cheaper somewhere too.

http://www.ebay.com.au/itm/Honda-CB550-CB550F-Engine-Oil-Seal-Kit-1974-1975-1976-1977-1978-550-Four-/380988988460?pt=Motorcycles_Parts_Accessories&hash=item58b4b69c2c&_uhb=1

[DaveBarbier]

Hmm, decisions decisions. I'll check it out tomorrow morning when I get back out there. I'll probably end up doing it because...when will the next time be when I'm in here. I'd hate to have it start leaking next season and think...crap, should have just replaced that.


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1978 Honda CB550K

[dave500]

its mostly those steel alignment dowels that rust and cause covers to be hard to remove.

[DaveBarbier]

Yeah, when ever I expose the dowels they're all pretty rusted up.


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1978 Honda CB550K

[DaveBarbier]

Clutch: Just doing some inspection while I have it out. The manual says to measure the thickness of the friction plate...singular. It means friction plateS, right? The main large one on the end is about 3.5mm and the other 6 are about 2.6mm in thickness. The spec minimum is 3.0mm. I just want to make sure I'm doing the right measurements. Looks like I need new friction plates.


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1978 Honda CB550K

[DaveBarbier]

About to split the cases. The manual says 12 6mm bolts but there actually 13, right? The secret one under the oil pan?

And it doesn't say anything about the top 4 bolts. Is the Honda manual better than the Clymer?


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1978 Honda CB550K

[calj737]

I always take multiple measurements on each disc, never relying on a single. At this point with the work you're doing, foolhardy not to replace the discs, plates and springs.

[DaveBarbier]

I took three measurements on each friction disc. Yeah I know what you mean. It's the smart thing to do. I'll have to price it out. The plates seem fine and within spec, but we'll see how much those are. Also springs are far from being out of spec. But again, if they're cheap enough then it's dumb not to.

There are also some scratches and wear on the clutch outer housing. Is this an issue?


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1978 Honda CB550K

[dave500]

those are just rough machining marks,note how those rivett ends aren't marked?

[DaveBarbier]

those are just rough machining marks,note how those rivett ends aren't marked?

Ah, smart. Sounds good, thanks.


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1978 Honda CB550K

[DaveBarbier]

So got the cases apart and after this picture took out my transmission. My transmission actually looks really good, minus the broken gear. I could just replace the gear and keep this one in, or just replace the whole thing. I'll probably replace the whole thing but I guess I'll look over both trannies and see if there's more wear I find.



Also, some crank bearings look pretty crap. I have plastigauge to heck clearances but what do you guys think? Here's a couple.


I'm also going to have to get a puller for this lower gear to take the primary and cam chain off, right? The manual shows a picture of what looks like a slide hammer that threads into the shaft.


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1978 Honda CB550K

[calj737]

Aren't you replacing the chains with new? If so, just cut them with a Dremel tool.

[Bootsey]

One of the long rear engine mount bolts will thread into the primary shaft. Throw a big socket on the bolt, and use it as a slide hammer.

[DaveBarbier]

Aren't you replacing the chains with new? If so, just cut them with a Dremel tool.

Thought about that...but I still have to get the new one on...am I missing something? The primary chain is endless so I'd have to get the shaft out to put the new one on.


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1978 Honda CB550K

[DaveBarbier]

One of the long rear engine mount bolts will thread into the primary shaft. Throw a big socket on the bolt, and use it as a slide hammer.

Ah, love it. I'll try that tomorrow morning before work. Or maybe I feel a sickness coming on and I'll "have to stay home". What happens in sohc4 stays in sohc4, right?


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1978 Honda CB550K

[dave500]

those bearings will be ok,just don't mix up their positions,use a marker pen.

[MickB]

Dave Barbier-  Oddjob suggested to me to also replace the rubbers in the primary shaft clutch, available from David Silver or CSMNL and not too exy.

[calj737]

Ah, love it. I'll try that tomorrow morning before work. Or maybe I feel a sickness coming on and I'll "have to stay home". What happens in sohc4 stays in sohc4, right?

Best remedy for work illness is to work on your bike. Hope you're feeling better not too soon, Dave.

[DaveBarbier]

Dave Barbier-  Oddjob suggested to me to also replace the rubbers in the primary shaft clutch, available from David Silver or CSMNL and not too exy.

You mean these? They seem cheap enough, but all this is adding up quick. I'll think about it. Considering my bike has under 10k miles I'm not sure how crazy I'll have to be as far as replacing parts goes.

It's "the wallet" vs. "I've already got it open" and it's a close fight.

https://www.davidsilverspares.com/CB550K-1978-USA/part_145156/


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1978 Honda CB550K

[DaveBarbier]

Ok, so just to summarize the new suggested parts that I should replace. Anything I'm missing?

Clutch Friction Discs
I'm looking at EBC.
(They're out of spec. but the plates and springs aren't. Since that can be done later when the motor is in the frame I'll wait on the plates and springs.)

Primary Sprocket Dampers
(Probably. Only because they'll only be about $30.)

Crank Bearings
(Not the connecting rod bearings. I don't think I want to have to replace the con rod stretch bolts for over $120 just to see if they're ok. I'll wait and see how far out of spec the other bearings in the crank are with plastigauge.)

Oil Seals
If I'm to replace the rubber main seals at the ends of the crank I'll have to get the big bolt off the rotor then pull the rotor which will be hard for me since the crank isn't held in place. I'll have to vice it or something. Maybe get an electric impact. Is it imperative to replace them?

If I do that I'm thinking of this oil seal kit off eBay. Thoughts? Plus, the PO probably put an o-ring chain on the bike for a short time and wore away some of that seal by the sprocket. It's not leaking but I think it's best to replace it, and it's in this kit I'm pretty sure.
http://pages.ebay.com/link/?nav=item.view&alt=web&id=380997819063
I want to get a kit but David silver spares doesn't have a kit and individually they're expensive.


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1978 Honda CB550K

[DavePhipps]

Aren't you replacing the chains with new? If so, just cut them with a Dremel tool.

Thought about that...but I still have to get the new one on...am I missing something? The primary chain is endless so I'd have to get the shaft out to put the new one on.


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1978 Honda CB550K

I'm doing the same thing so I'd like to find out how that would work.