Topic: Hitting the Ground Running = New Member +'76 CB550 Barn Find + First Ever Build

[MTRD3]

Well, this is certainly a first… I don’t think I've ever joined a forum and made an introductory post and I certainly have never built anything before so here goes lol.

I’m sure this is an all too familiar story to most of you. For years now I've had to suppress aspirations of building my very own bike. I've been riding for several years but only with modern “R” bikes. I somewhat split bikes into two groups that I’m passionate about… sport/”R” bikes and vintage/café/scrambler/flat tracker style bikes. Being a student meant that more than one bike was not feasible and, as such, I went after what the young me yearned to possess... a “crotch rocket” (for lack of a better term).

Fast forward a few years and two things happened which have brought me to where I am now. One, I fell victim to a piece of advice which I routinely received from some good friends… “The day you track a sport/race bike will be the day you give up street riding one” and two, the ROI of my student years proved their worth and I could now afford to pull my dreams of building a vintage retro-mod bike out of the bottom drawer.

I joined the forum a few months back and just began reading other peoples build threads and trying to learn about the art of retro-modding a CB. At the same time I casually searched for one with the hope of finding a barn find to serve as the interesting tidbit that so many builds have started from. Last month an interesting sequence of events made that hope a reality and earlier this month I became the owner of a 1976 CB550K which had been sitting in the back of a barn since 1989.

With access to some rented work space, I took the first steps of my build last weekend and started taking the CB apart. I know I don’t have to provide much reasoning here as to why a CB, but in short, my old man always rode CB’s and I grew up hearing about how great they were/are. He also owns a CB750 Super Sport, CB900 and a prize possession CBX which lead me to thinking I ought to go with a CB350/2 or a CB550. Having zero experience with mechanics, engineering, builds, fabricating or anything of the sort I thought the CB350 would be the way to go if I wanted to make things easier on myself. Contradictory to that thought, I decided that a build, the way I’d always envisioned it, would be something that I could enjoy and invest a lot of myself into (as well as take away from) and as such I ought to do away with the idea of a “tune up” build and instead go straight into what may seem like biting off much more than I can chew by attempting to build exactly what I've always wanted. With the marvels of technology a.k.a. this Forum, Google and Youtube serving as three of the greatest tools one could hope to have I figured I was short on excuses as to why I wasn't in any way fit or qualified to undertake a build and should be looking for a builder to hand the bike and my money over to while simultaneously robbing myself of a fantastic opportunity to learn and make what are sure to be some great memories.

I already have a bunch of rudimentary questions but the best part about the past few months spent as a lurker on SOHC.net is that the general atmosphere has seemed so friendly/indicative of a common willingness to help based on peoples love for the CB’s, that I don’t feel too bad to admit that I don’t know much but am more than willing - as a matter of fact excited - to learn from each “dumb question” asked.

Well fellas, here goes… bear with me lol.

You can’t get away with a long winded intro like this without having any pictures - first two are from the day I picked it up and the other two are from my first day at work (last Saturday) where I started and left off after a few hours (not seen in the pic is that I got the carbs off the motor as well).

[MTRD3]

Some specifics about the build which I've already decided upon are:

- Upside down front forks (from what I've read I've started looking for PC37 CBR600 parts or GSXR equivalent)
- Complete with dual disc front brake setup
- Corresponding rear disc brake setup
- The other original CB550 Tank I've seen which has a chrome looking flip-up gas filler cap
- New rims choice
- Other typical details to a build such as custom seat, sets, handle bars, instrument setup, headlight, tail light as well as front and rear indicators.

I had thought it would be fun to open up the engine and take a look around while renewing anything that would prove beneficial to renew but I'm hoping to get some feedback here in terms of to what extent. The bike has just over 20,000 orig. km's but obviously wasn't running when I picked it up. It hasn't ran since 1989 and the carbs were not connected to the airbox... in addition there were a few disconnected hoses etc. which I was unaware of what they were. In hindsight perhaps I should've tried to get the bike running first to see where things stand but I imagined the carbs would need a lot of attention before the bike could run and as such I figured why not just take the whole thing out, buy an engine stand and start exploring/learning. At this point I'm somewhat assuming that I should really only have to go through the top end of the engine but again, I'm really just making general assumptions.

[MickB]

Welcome & good luck MTRD3, I'm glad to see you pulled that pack thing off the bike first - put it on ebay and good riddance.

Make sure you bag/ box every part and name where it's from as your build is going to take a while. Read other 500/ 550 builds and see what they've done, particularly the tips area of the forum.

My advise, see if you can do a little each day as the whole project can be a bit daunting, but little by little and you'll get there. Don't put too much pressure on yourself to get things done quickly as you'll come up against little things that'll take time to repair/ restore.

Regards
Mick

[MTRD3]

@MickB: Thanks for the well wishes and advice. There are a few principles which I applied to my planing before starting the build. Things like take photos as needed, label and box up everything while keeping parts that belong together boxed up together, ziploc bags and labels for smaller parts and anything carb or engine related and trying to learn/understand how something works, or better said its function on the bike, before taking it apart. The theme is to try to be diligent with the tear down with the hope that it pays dividends in my understanding of how to best approach the reassembly/resto-modifications.

A key facet to the build is that I haven't put any set time line on it and don't want to set a deadline/stress over time at all. I can only work on the bike on Saturdays (my career doesn't allow for it Mon-Fri) and as such I just approach each day with a "do/achieve what you can" mentality and thirst for learning. Another thing that I think might be cause for delay is waiting on parts to arrive or searching for the specific ones I want/need (for example, the entire front end modification).

[flatlander]

i would first get the bike run reliably and safely, and think about everything else later. you'll have enough work with that for a while, before turning to any mods. it actually doesn't look that far from stock so getting it close to that and back in good shape could be a starting point.

[SOHC4 Cafe Racer Fan]

It looks like you actually have a 1977 CB550K3 model.  It is VERY likely you have a K3 model that was sold the year before (it's very common once you are at the tail end of a year for a dealer to start selling next year's model.  Neither your frame nor your tank are from a 1976 CB550K2 -- your rearset brackets, dash and gas tank are all from a 77 or 78 model.  No big deal, but a good thing to know.  Almost all of the parts interchange.

[rb550four]

MTRD3, Welcome. The very first thing every newb should do without question is either download or purchase a shop manual... thumb through it look at the pictures, and spot read...find things in the manual you expect to doing and give it a good once over pointing out where these parts should be on the bike, so you get comfortable with both the bike and the manual.
  Put the manual down and take off the carbs, if you don't know how ,look it up . the manual is logical. Find and order a battery, 4 carb rebuild kits, 2 oil filters, plugs, points and condenser unless you want electronic, oil any brand because you will be dumping it out soon, I have found that oil filter nuts are usually buggered up from POs so I keep a new one on the shelf.
1/4 "drive metric socket set, 3/8" drive metric socket set w / 3", 2-6"extendtions , and metric gear wrenches up to 19mm, feeler gauge, impact and extra phillips bits, a dead blow hammer just to get started, you'll need more as you get into it.(this stuff is on sale everywhere this week).Penetrating oil, ( I like a propane torch sometimes) , a test light and multi meter for electric now.
  Valve spring compressor, buffing machine, bike lift of some sort, sync gauges for later....
These are items to spout off if your Santa needs to know what you would like.
  Go through the fuel system, inside the tank condition, fuel cock, carbs.
Electric: New battery, points ,plugs,timing... Clean any contacts that you come across everywhere on the bike, check fuses... Make it all work.
  Engine change oil, filter , check valve clearances, adjust cam chain ... You could pull the pan if you are hunting for signs of wear and checking the condition of the primary drive chain, but you don't have to yet, unless you are interested.
Get it running to your satisfaction so you know what you have to work with , then take it apart and make it the machine it should be.
   It should always be fun ...it may not be easy for your first time... ask questions here if you're stumped, but always take pics .

[Restoration Fan]

That's a great advice post, rb550four.

[seanbarney41]

Let me run this one by you...you already have a crotch rocket, right?  Why go messing around trying to make this into a crotch rocket, i.e. upside down forks and all that stuff.  It will never compare to your modern bike anyway.  Maybe you could learn to appreciate the old stuff about this bike that make it special and choose more period correct upgrades.

whatever you do, enjoy yourself, and welcome to the forum.

[ekpent]

And save some money and hold off on the 'carb rebuild kits', maybe just get some bowl gaskets for now. Some kits are crap and you will probably need to jet and tune to go with any mods you may be making in the future anyways.
  I am not a 550 expert but isn't that an F or Super Sport model ?

[mrfish2]

It looks like you actually have a 1977 CB550K3 model.  It is VERY likely you have a K3 model that was sold the year before (it's very common once you are at the tail end of a year for a dealer to start selling next year's model.  Neither your frame nor your tank are from a 1976 CB550K2 -- your rearset brackets, dash and gas tank are all from a 77 or 78 model.  No big deal, but a good thing to know.  Almost all of the parts interchange.

Looks like an F model to me from the design of the seat and the 4-1 exhaust (if it's stock). The only thing pointing away from it being a 76 is this bike has a black seat instead of dark brown. The tank looks to be correct too, just the pin-striping has either been pulled off or peeled away. There should be a gold stripe below the black paint on the tank and if you look closely it looks as if it used to be there.

Also, this looks to be a Euro model too and they made 'em different over there.

[goldarrow]

75, 76, or 77 550F.  Pick one. 

[MTRD3]

Thanks for warm welcome and advice fellas! I made a typo in my original post, the bike is indeed a CB550F and not a K model. The 4-1 it came with is the original Honda part and is in great shape. Something tells me that must have some value (?) so I boxed it up and plan to keep it in storage just because I think it's nice to have.

@Flatlander: In hindsight I kinda wish I had taken that approach.. would've been interesting and definitely good for my learning curve to have tried my hand at trouble shooting. That being said I'm a bit too far to turn back now.. engine is already out of the frame and on a small dolly. With the build I plan to approach the carbs near the end to tie everything in together, so I guess this way I avoid having to attend to them twice because I think they would've needed an overhall in order to get the bike running... can't say for certain though.

@RB550Four: To echo "Restoration Fan", that is a great introductory advice post and served as a good follow up check list for what I've considered prior to starting this adventure. One of the first things I did when I found this forum (prior to having the bike even) was download two or three of the manuals for the CB550 as well as a wiring diagram. I actually used the manual to assist me in the engine removal... the steps and pictures in the manuals allowed for things to go very smoothly.

I'm also lucky that two friends of mine have a private workshop in a barn for their cars and when they were looking for a third to split the rent with I jumped in. The shop is a fully equipped mechanics shop with hoists, tools, etc. So although I do have a fair bit of tools at home, this saves me having to lug them around and I have access to more because the shop has a lot more. Things I bought this week which I didn't have are, as you mentioned, a valve spring compressor and a motorcycle lift/stand & separate engine stand.

@Seanbarney - I absolutely understand and can relate to that POV. Two things that did factor in to me deciding to make this a resto-mod are:
1. I actually no longer have a sport/R bike.. sold my last about a year and a half ago after a summer of almost only track riding. I want to get back to track riding at some point, after I build my dream CB, and have saved up again to be able to have a second bike obsession.
2. My old mans CB's are all original and I figured with this being the fourth CB in the family it would be ok to turn into a build. I'll attach a pic I just found on this laptop of two of his three (don't have a picture with the CBX in it) 

@Ekpent - Yup, I plan to go through the carbs last in order to ensure that they are tuned to match the near final result of the bike/build.

@MrFish2: Good eye, I actually live in southern Germany although I'm from Canada. Being out here posses the issue of parts procurement because I still migrate to the parts and forum scene(s) in America/Canada which means shipping woes (already found some Sun/Buchanan rims I want which means international shipping unless I acclimate myself to the parts market here in Europe). I'm not too familiar with the differences between a euro vs. american model CB550F but would love to find out.

[flatlander]

if you have the original exhaust incl. muffler don't chuck it, they are getting rare. at least here in europe.
i'm in the netherlands, by the way. so my 76 550F is also a euro model, you can see it here: http://forums.sohc4.net/index.php?topic=134863.0

it's getting harder to find examples of these bikes that have not been turned into a cafe or whatever. parts you add now will depreciate, no matter how fancy they are and then it's still just a 40 year old bike with some mods while the original stuff is getting more precious. might be something to keep in mind if you're interested in resale value, at some point.

[FunJimmy]

Welcome aboard. Nice to see that you chose the right bike for your project. The 550's have the perfect power to weight balance and remain one of the most agile of the family.

I'm a fan of stages. Start with getting it running first. Then work on your top priority. Finish up in the spring so you can ride the summer season and determine the next phase. Lots of progress can be made off bike through the summer riding season too.

Most importantly, have fun.

[Stev-o]

Welcome from Texas.  The 550F was my first SOHC, great bike. 

[SOHC4 Cafe Racer Fan]

I love my 550 -- it is extremely nimble, although I wouldn't mind having about twice the power.

[Restoration Fan]

Welcome from Texas.  The 550F was my first SOHC, great bike.

Steve-o, what part of TX?  I'm in Amarillo tonight and driving through Dallas tomorrow on my way back to Georgia eventually.

[Stev-o]

Welcome from Texas.  The 550F was my first SOHC, great bike.

Steve-o, what part of TX?  I'm in Amarillo tonight and driving through Dallas tomorrow on my way back to Georgia eventually.

I'm near Austin, "only" about 495 miles south of Amarillo. Wanna stop by for a beer and talk shop?!

[SOHC4 Cafe Racer Fan]

Welcome from Texas.  The 550F was my first SOHC, great bike.

Steve-o, what part of TX?  I'm in Amarillo tonight and driving through Dallas tomorrow on my way back to Georgia eventually.

I'm near Austin, "only" about 495 miles south of Amarillo. Wanna stop by for a beer and talk shop?!

I enjoyed my trip to Austin immensely -- to attend ACL.  A truly awesome city and you can't beat the Salt Lick!!

[cwchan]

Some specifics about the build which I've already decided upon are:

- Upside down front forks (from what I've read I've started looking for PC37 CBR600 parts or GSXR equivalent)
- Other typical details to a build such as custom seat, sets, handle bars, instrument setup, headlight, tail light as well as front and rear indicators.

i installed cbr600rr forks and i am very happy

If you're going with a custom seat i'd be interested in that stock seat you have there.  Where are you located?

[Restoration Fan]

Welcome from Texas.  The 550F was my first SOHC, great bike.

Steve-o, what part of TX?  I'm in Amarillo tonight and driving through Dallas tomorrow on my way back to Georgia eventually.

I'm near Austin, "only" about 495 miles south of Amarillo. Wanna stop by for a beer and talk shop?!

Lol, I'll take you up on that another time.  Went on through Dallas to Shreveport today so I could make it to the family tomorrow in time to leave for Thanksgiving with the in-laws.

[MTRD3]

No No, this won't be one of those builds that started out with lofty aspirations only to be abandoned.. My schedule finally allows for a return to the CB550 (after Easter lol). That's not to say it has been out of sight out of mind.. with all the travelling I've had to do professionally, I've spent my fair share of time on flights reading manuals and other information sources, free time here on the forum amongst the plethora of information that's been archived, and any down time at home on Youtube as a visual learning reference (particularly watching a channel called "Hackaweek" because the guy, Dean, has done an amazing job filming the rebuild/assembly of his CB750... mentions also being a member here!).

I've made a few determinations that weren't part of the initial plan.. most notably, as a result of reading numerous paulages & hondaman posts/threads, a plan to incorporate some CB650 parts into my motor rebuild and aim for a bit more displacement (and all the fun stuff that comes along with it).

I've been let down three times in four months via Ebay while trying to procure the tank I want for the build (the version with the vintage looking chrome cap.. but am chasing a good lead on one now. The euro plummeting against the dollar has been an annoyance because it's proven much easier to find the PC40 CBR 600 front suspension in the states than anywhere here in Europe.. but I'm not in a rush as far a suspension goes so that's ok.

As things stand with the bike frame etc. (motor is open on a stand in my little 10x8 basement workshop) It seems I'm at the point of wiring and electrics.. which I'm approaching very apprehensively because it's the part I was looking forward to the least and feel most in the dark about. I'm going to post up some pictures here with some questions about stuff I've seen this far and appreciate any input as usual.

T.I.A.

In order, Pictures 1 & 2:
First bit of electrics on the bike that I've uncovered and need to look into.

Pictures 3,4 & 5:
Some loose tubes I noticed when prior to engine removal (and not disconnected by me) as well as a detached cable which looks like the throttle to carb cable. Not sure what the two tubes which are next to one another are, but the third one with I followed to the top of the engine so I imagine it has something to do with a breather type setup.

Pictures 6, 7, 8: Further foray into the world of electrics.

Picture 9: Took the bottom end off (after doing some reading) to look at the primary chain and sprocket... which in my inexperienced opinion look to be in good shape.

[MTRD3]

And a much more exciting post... did finally get one part that I had ordered back in November and waited anxiously to get word that it was ready (although I did learn of the issue I know have in terms of using a CB650 head for the motor rebuild  )  :

[MTRD3]

Well, as alluded to in my last post, my lovely Motogpwerks exhaust does come with its sacrifices it seems (although it's actually my decision making which is to blame lol). I had decided I wanted to go the route of using a CB650 head (and possibly crank) in the rebuild of my 550 engine, but learned that the exhausts for the two bikes are incompatible. I haven't measured my MGPW exhaust but until I can get to that tomorrow I imagine it is going to present the same issue seeing as it is made for a 550. I found the following great info. here on the site:

ID of a 550 pipe 27mm, OD 38mm / 550 head has 27mm exhaust ports
ID of a 650 pipe 30mm, OD 42 mm / 650 head has 30mm exhaust ports

*Spacing of the ports from a 650 to a 550 is 2mm smaller.

A post from Paulages provided this great info:

    ID at throat         pipe O.D.       flange O.D.     flange I.D.

550F             25.4                   31.8              37                 28.3
650              28.6                    34.7              40.9              33


Which led me to think about something custom like an exhaust coupler/flange that had the 650 head diameter on one end and the 550 header diameter on the other to allow them to connect. Has anyone seen something like that? Or would it cause problems with clearance/offset spacing and possibly sealing?

Another concern is whether or not the 550 header would actually be detrimental/restrictive in terms of performance if it's 3.2mm smaller in diameter. Although it sounds small it's more than 10% of the total 650 diameter. I also read that the 650 pipes cross section is 127% bigger than the 550's ~ a 27% reduction in cross sectional area.

Would love to hear from some of the many experts here on the board         T.I.A.