Topic: Will's 1971 CB500 Build

[skyline223]

Good day!   What is that car? 50's Ford??

1956 Chevrolet Bel Air I restored about two years ago!

[SOHC4 Cafe Racer Fan]

Once you have the tank prepped and cleaned the inside of rust you might want to line it with Caswell epoxy to prevent rust.

[skyline223]

Once you have the tank prepped and cleaned the inside of rust you might want to line it with Caswell epoxy to prevent rust.

Ah yes forgot to mention that was another primary reason for stripping the outside. I am about to do a full treatment and seal job on the inside.

[Stev-o]

Good day!   What is that car? 50's Ford??

1956 Chevrolet Bel Air I restored about two years ago!

Beautiful!

[skyline223]

Beautiful!

Thank you sir!!

[SOHC4 Cafe Racer Fan]

Good day!   What is that car? 50's Ford??

1956 Chevrolet Bel Air I restored about two years ago!

Beautiful!
No kidding! Gorgeous!

[calj737]

Only if you're into meticulously restored, painstaking effort on resurrecting a true American Classic and piece of motoring history... Otherwise, looks just like my wife's first car; '91 Nissan Sentra with mismatched doors and hood from the junkyard, a cracked windscreen, and no mirrors. 


Beautifully done, Will! I'll bet your bike will be a treat to behold too!

[skyline223]

Thanks Cal!! Checked out your build thread.. wonderful bike you have built. I love the style.. and good luck on the continued repairs. I know that is no fun...

I got just a couple hours to tinker on the bike tonight. I began the process of epoxy sealing the inside of the tank, and while I was letting the various chemicals soak, I decided to begin the saga of getting the electric start to work.

I got a new start switch in the mail from 4 into 1. I went ahead an removed the headlight housing so it would be as easy as possible to work on the wiring. The broken start switch that was on the bike has had all of its wires cut from it, so I have no "starting point" to know what to connect.


I went ahead and played "connect the colors" on the wires that I could, which was most of them. The headlight high/low beam is functioning correctly, but the black/white striped wire has me a bit confused. It comes with a female connector but I am not finding a unused male black/white coming from the main harness. There is ONE coming out but it is occupying a dual female connector... with an open female port... and I need a free male for this to make sense.. Anyhow if I haven't confused you yet, let me know where this wire goes!



In addition, I noticed this heavy gauge wire coming out of the block, presumably from the starter. It is currently hanging out connected to nothing. Where is it supposed to go?

[calj737]

First thing first, Will-

Print this out in color, and blow it up as large as you can; it makes it much easier to follow http://manuals.sohc4.net/CB500/CB500WDC

The BLK/WHT should be coming from your KILL switch and leads to the ignition coils.

I believe that heavy gauge wire from your starter should be heading to battery POS. Check if you don't have a connection there. It may have been removed when the electric start button was disabled. And be sure to clean the ring terminal on it prior to installing.

[skyline223]

That wiring diagram is a huge help. Thanks!!!

I connected the heavy gauge wire coming from the crankcase and the starter just started running as soon as contact was made. I'm guessing it needs to connect somewhere else (starter solenoid) so that it can be controlled by the start switch?

The bad news is that when the starter was running, it was not turning the motor. Just sounded like it was free running without being engaged... I don't know really what the design looks like in there (soon to find out I am sure) but it sounds like on a car when the starter runs but the bendix does not engage on the flywheel.

[Stev-o]

That may be your starter clutch gone out. Not good.

[calj737]

Yup, probably why the starter was removed.... You can replace it while the motor is in the bike, there's a few threads in here about doing it. Takes about an hour the second time you do it and know the trick. About 2 hours the first time...

[skyline223]

Yikes. Well like all things I knew there would be a reason for the switch being gone and the lead being loose. Well hopefully it won't be too much of an issue to fix. Kickstart will have to do for right now!

I had a little time to work on the bike today and made some decent progress. I've spent a good amount of time detailing the engine. You can see the fruits of my labor... so far so good! I'm happy with how it is cleaning up. I took the points cover off, banged out the dents, and painted it nice gloss black. I am also painting the valve tappet covers black.

I also was able to reinstall the header. I am really happy how it is all looking with the black theme going on.

And in other exciting news I recieved my carbs from 2strokeRush today! I just threw them on there to get a look at everything together. Thanks again man, it was a pleasure!

I also received my ignition switch bracket from calj737. I can't thank you enough for the generosity! Hopefully I can find some time to get all these parts on the bike for good!

Thats all until next time...

[2strokeTrush]

Get to work son!

[skyline223]

Been hard at it today! First off I thought this was an interesting photo after I had detailed the right side only of the engine...



So I got going getting the left side of the bike detailed. In addition I was able to get the carbs, air box, and ignition switch all installed!



Time to get into the not so fun stuff... bodywork. I have spent the better part of the day bodyworking the tank. Maybe a couple more coats of primer and it will be ready for topcoat!


I am going to try out the Legendary Motorcycles custom side panels purchased from Dime City
http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-body-work-side-covers-legendary-motorcycles-cb500f-cb550f-sc1752.html

These required a decent amount of trimming to fit, but I have them just about ready for final paint now.



Until next time...

[2strokeTrush]

How did you get that side of the motor so clean!?

[skyline223]

How did you get that side of the motor so clean!?

First I hit it with the popular engine foaming degreaser, then I used Purple Power cleaner/degreaser and a nylon detail brush to get anything that was left. At that point it looked pretty darn good but here's what I did to take it just a step farther...

I masked off the frame and chrome covers, wiped it all down with acetone and then DUSTED a coat of VHT aluminum engine enamel on it. Just a very very light coat to unify the overall look. It was a bit of an experiment but I think it will work!

[2strokeTrush]

How did you get that side of the motor so clean!?

First I hit it with the popular engine foaming degreaser, then I used Purple Power cleaner/degreaser and a nylon detail brush to get anything that was left. At that point it looked pretty darn good but here's what I did to take it just a step farther...

I masked off the frame and chrome covers, wiped it all down with acetone and then DUSTED a coat of VHT aluminum engine enamel on it. Just a very very light coat to unify the overall look. It was a bit of an experiment but I think it will work!

wow good work! And you had time to paint my carbs! Looks good though, I did something similar with my 350f carbs!

[skyline223]

Thanks man!! Yeah just painted the top covers and float bowls, thought it would tie everything in a bit!

[Tews19]

The engine work is very impressive!

[SOHC4 Cafe Racer Fan]

That's a great in frame engine clean up.

[skyline223]

Thanks so much, guys!

Well today I made a good amount of progress. Lets see if I can remember all the way back to early this morning when I got started...

I was contemplating on whether to paint the tank and side covers gloss black or satin black. After seeing this bike, which I liked very much, I was leaning towards the satin look.

http://silodrome.com/honda-cb550-cafe-racer/

So I did something you aren't supposed to do.. I asked my woman for her opinion. In my experience of taking her to car shows she (and I) is not usually fond of flat blacks or satin blacks. But to my surprise she said she preferred the satin for the bike. Well I've learned that what SHE says goes so satin it was!

The tank and side covers were shot satin black. And I am loving it... gives the bike a very mean attitude I think, but doesn't come off looking cheap or thrown together (as I feared it might with satin).





In the mean time I painted the forks satin black as well as the rear shocks. I don't want to go overboard with black but I personally think everything it looking pretty good so far. You'll notice that the hot-rodder in me also removed the front fender. I'm sure I'll get some rocks in the face for it (TN requires facial cover anyway) but I think it just adds an aggressive edge.. will be even better with some new tires!

I also got some new mini turn signals!


So... I don't know much about the bike world... and I figure I may risk being burned at the stake for the next part. But here it goes...

I couldn't help but add some LED accent lights to the underside of the tank, on the bottom of the frame, and under the rear fender. In my own defense they are WHITE only and they DONT BLINK 



I wired them all to a lighted rocker switch under the tank. I also added a quick disconnect plug at the tank for easy tank removal.

So that is all for today.. tomorrow I should be getting my new straight handlebars in the mail and can begin the process of getting everything installed. I have also ordered an LED lucas style taillight as well. Hopefully I can get this bike on the road within the next week if all goes well!

[skyline223]

The checkered flag is in sight!!...

Lots of great progress made in the past couple days!!!

Yesterday I spent most of the day installing my new drag bars. It was a time consuming process drilling all of the holes and routing the wires through the bars, but all in all it wasn't too bad. I love the look! In the mean time I also threw on a new lucas LED tailight.

This morning I ran all my new throttle cables as well as a new clutch cable. Then.................  it was time.

Fuel petcock to on - kill switch to on - ignition on - a few kicks to the kickstarter.. VICTORY! She roared to life!

I'm still grinning ear to ear from listening to her run! I can't contain my excitement! After letting her idle for a bit I attempted to shift into first.. no joy. She just stalled out... back to the garage.

I took apart the side cover again and inspected everything. To my untrained eye all seemed normal, but I could tell that the clutch lever wasn't deactivating the clutch simply from the feel. So I got on the forum here and did a quick search. I quickly found out about the 5/16 ball bearing that is supposed to be at the end of the clutch lifter rod. I didn't have it..

So a quick trip to the hardware store to get one, pop it in, and as easy as that we have a clutch! So I rode her around my yard about a dozen times. Man is this fun!!!

Now all I need is a new set of tires, insurance, and we will be going for a ride!!!!!

(Excuse the masking tape on the tach, still waiting on a set of new gauge overlays and then I will button them up for good.)

[calj737]

 Well done, Will.

Bear in mind these are air-cooled engines. So don't let it idle stationary for extended periods while you tune it. If you must, use a hi-flo fan pointed at the motor/exhaust area to help dissipate the heat.

[skyline223]

Well done, Will.

Bear in mind these are air-cooled engines. So don't let it idle stationary for extended periods while you tune it. If you must, use a hi-flo fan pointed at the motor/exhaust area to help dissipate the heat.

Thanks for that tip. I was wondering about what the tolerances were there. I only let her run about a minute sitting still. Definitely good to know.

Tonight I got the gauges finished up.



I also took her for a short spin around the neighborhood block. She shifts smoothly into every gear... what a blessing!