Author Topic: 1972 CB500 - Rebuild Project  (Read 31995 times)

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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #100 on: September 25, 2015, 09:23:33 PM »
The question is how to deal with this?

Not sure if it's even possible to find new-old-stock although the Part# 42610-323-000 seems to be the same for the CB500's and all of the CB550's so that  increases my chances.

I've sent the feelers out to see if I can find a low-mileage second hand part locally.

I guess the other option would be to see if a machine shop can insert a bush or a sleeve to bring it back up to the original thickness?

Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #101 on: September 26, 2015, 11:32:32 AM »
Thanks Cal...  much appreciated.

Yes it was actually Deltariders post that led me to this point.  Another win for the forum methinks...
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #102 on: September 30, 2015, 03:44:30 AM »
So I'm over in another part of town this afternoon and i'm heading back to my van when out of the corner of my eye I see a small sign pointing down an alleyway indicating a Motorcycle Breakers.  Luckily I had my worn-out final Drive Flange in the back seat so I wander down fully expecting to walk back out the alleyway 2 minutes later with nothing lost but nothing gained.

Once there I was barely acknowledged by a rather short and incredibly grumpy old man who seemed nothing short of inconvenienced by the fact I'd come down to his place of business to potentially part with some money for something he made a living from selling.  Anyway, when I asked whether he had a 1970's CB500 he was breaking he surprisingly replied with "... only the back wheel".

The brief glimmer of hope that I initially had was soon quashed when he appeared from round back holding a rear wheel assembly that looked like had been outside in a puddle for the last 30 years.  Undeterred I asked for some tools to start taking the hub apart to examine the condition of the drive flange....

Despite acting like I'd asked him for a go on his teenage daughter, he eventually provided the necessary equipment and watched me for 20 minutes as I disassembled the rusted up and greasy pile of crap whilst trying not to get #$%* all over my best shirt and business attire.

When I finally got the drive flange off, and managed to convince him to part with an old rag to clean the part up, I found that somebody had already had the same problem as me but resolved the issue by machining a bronze bush that sat neatly inside the flange.

Eureka..!

"ll take this please"  I said
"No.. it's the whole wheel for $120 or nothing" he said
"but I only need this and the rest of the wheel is junk" I say
"fine I'll throw it in the skip" he said
"..........?" I said
"Ï told you it's $120 for the whole lot" he said
"yeh... but now I've just taken it apart for you?" I say
silence
"I'll give you $40 for the lot" says I
silence
"fine... hold onto it for another 30 years" I say

Then he starts putting the whole thing back together

....after another 10 minutes of childish exchange I start to walk away and he calls me back and we agree on $75 for the whole wheel.

I ended up with working drive flange, plus a spare hub, rim, cush rubbers and bearing retainer... all of which I don't need....  and he got lucky and made $75.

To be honest I would have spent more than that at a machine shop plus the arse of driving around town for the next couple of weeks so I'm generally happy with the outcome.  I had a number of breakers contact me to say they had spare flanges but they were all worn just like mine so I was running out of options.

Anyways... pictures below... all fits perfect and no more sprocket wobble...





« Last Edit: September 30, 2015, 08:52:34 PM by Puffin »
Honda CB500 four
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1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #103 on: September 30, 2015, 03:45:33 AM »
More pics.... Bit of a clean and a polish and I reckon it will come up real nice
« Last Edit: September 30, 2015, 03:54:11 AM by Puffin »
Honda CB500 four
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #104 on: October 05, 2015, 09:12:08 PM »
Now I've sorted those problems out I have a new found enthusiasm and I'm getting this thing back together at record speed...

Drive Flange came up almost as good as my original and the rear wheel is back together and working perfectly. 

In the Honda Service manual it states that you should grease up all contact surfaces in the cush-drive.. something not mentioned in the Haynes and Clymer manuals.  Makes sense given there are 0-rings and grease grooves in the hub and flange.  I guess you don't want to over do it because there are holes into the Drum Brake side of the hub so you really want to avoid this seeping through onto your brake shoes.

Ended up treating myself to a new set of sprockets as well
« Last Edit: October 06, 2015, 02:35:39 AM by Puffin »
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #105 on: October 05, 2015, 09:21:26 PM »
I've had these really classy front indicator lights for some time... I think I got them from 4into1.com about a year ago?

They have a really good quality, flat black metal shell and are really bright... what really like about them is that they match my headlight perfectly.  I mounted them with a simple bracket.

Definitely digging the flat black and chrome look that's developing.
Honda CB500 four
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1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #106 on: October 05, 2015, 09:34:09 PM »
I ended up taking my Carbs back off because I wasn't happy with the way I originally bench sync'd them.  Since originally restoring them I have read up on it a lot more using the info in this Forum so I took the time to do it properly using a 3mm drill bit to balance the throttle slides whilst remembering to have the idle screw turned about half way so that I had plenty adjustment available on the idle screw when it comes to the final vacuum balancing.

I also took the time to fix the broken pin on the backing plate and eliminate the side-to-side movement along the bar that holds the throttle slide arms.  This involved drilling out the broken pin and inserting a new pin.  I tried a number of things but ended up using a ridged nail cut to about 11mm in length.

It's not Grade-A engineering but it works perfectly and to me perfect is good enough....

Honda CB500 four
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #107 on: October 05, 2015, 09:47:15 PM »
My tank is currently getting painted so I thought I'd work on the Petcock and gas cap.

I did strip the tank and fill out the dents and I was prepared to paint it myself but you can't get the Spraymax type 2-part paint in rattle cans in this country so I was limited to a standard lacquer clear coat which would melt the second it got a whiff of fuel near it. 

The bike deserves a quality finish so I dropped it off at a little place down from my work and he's gonna do a proper job for me..

I had this gas cap with a fuel gauge in it and it looks like a cool idea on the surface but the reality is a bit different.. for a start it's #$%* and doesn't actually work..  the weight of the float is not enough to pull the needle down to empty and it has this massive hole underneath which looks like it would let gas through every time you moved with a full tank.  I spent a good couple of hours trying to make the thing work but in the end I stopped wasting my time.

Settled instead on a new classic, cool, Honda, period original gas cap....
Honda CB500 four
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1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #108 on: October 05, 2015, 09:54:11 PM »
Got some new o-rings, fiber washers and a filter for the Petcock and gave it a good clean . 

I'm sure you can get fibre washers from a hardware store but I couldn't find the dimensions so I just bought a couple from Honda for now and made a note of the dimensions for future refurbs...  see picture for details. 

« Last Edit: October 05, 2015, 09:58:35 PM by Puffin »
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #109 on: October 05, 2015, 09:57:59 PM »
Once again that product detail is as follows...

Make sure you enunciate clearly when ordering over the phone.... ;)
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Offline SOHC4 Cafe Racer Fan

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Re: 1972 CB500 - Rebuild Project
« Reply #110 on: October 05, 2015, 11:22:50 PM »
My tank is currently getting painted so I thought I'd work on the Petcock and gas cap.

I did strip the tank and fill out the dents and I was prepared to paint it myself but you can't get the Spraymax type 2-part paint in rattle cans in this country so I was limited to a standard lacquer clear coat which would melt the second it got a whiff of fuel near it. 

The bike deserves a quality finish so I dropped it off at a little place down from my work and he's gonna do a proper job for me..

I had this gas cap with a fuel gauge in it and it looks like a cool idea on the surface but the reality is a bit different.. for a start it's #$%* and doesn't actually work..  the weight of the float is not enough to pull the needle down to empty and it has this massive hole underneath which looks like it would let gas through every time you moved with a full tank.  I spent a good couple of hours trying to make the thing work but in the end I stopped wasting my time.

Settled instead on a new classic, cool, Honda, period original gas cap....

I have one that I tried as a novelty.  The problem with mine is that the latch is a PITA to release.
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #111 on: October 06, 2015, 02:49:15 AM »
Quote from: CB750 Cafe Racer Fan link=topic=145835.msg1736885#msg1736885 date=1444112570[/quote
I have one that I tried as a novelty.  The problem with mine is that the latch is a PITA to release.

It's a shame because I really wanted to use it... I didn't even care if it worked but when I filled the tank with water to check for leaks the thing just leaked out the top when I moved the tank about.  I just didn't want to take the risk on my newly painted tank.  .

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Honda CB350 four (under construction)

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Offline Restoration Fan

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Re: 1972 CB500 - Rebuild Project
« Reply #112 on: October 06, 2015, 04:31:57 AM »
So I'm over in another part of town this afternoon and i'm heading back to my van when out of the corner of my eye I see a small sign pointing down an alleyway indicating a Motorcycle Breakers.  Luckily I had my worn-out final Drive Flange in the back seat so I wander down fully expecting to walk back out the alleyway 2 minutes later with nothing lost but nothing gained.

Once there I was barely acknowledged by a rather short and incredibly grumpy old man who seemed nothing short of inconvenienced by the fact I'd come down to his place of business to potentially part with some money for something he made a living from selling.  Anyway, when I asked whether he had a 1970's CB500 he was breaking he surprisingly replied with "... only the back wheel".

The brief glimmer of hope that I initially had was soon quashed when he appeared from round back holding a rear wheel assembly that looked like had been outside in a puddle for the last 30 years.  Undeterred I asked for some tools to start taking the hub apart to examine the condition of the drive flange....

Despite acting like I'd asked him for a go on his teenage daughter, he eventually provided the necessary equipment and watched me for 20 minutes as I disassembled the rusted up and greasy pile of crap whilst trying not to get #$%* all over my best shirt and business attire.

When I finally got the drive flange off, and managed to convince him to part with an old rag to clean the part up, I found that somebody had already had the same problem as me but resolved the issue by machining a bronze bush that sat neatly inside the flange.

Eureka..!

"ll take this please"  I said
"No.. it's the whole wheel for $120 or nothing" he said
"but I only need this and the rest of the wheel is junk" I say
"fine I'll throw it in the skip" he said
"..........?" I said
"Ï told you it's $120 for the whole lot" he said
"yeh... but now I've just taken it apart for you?" I say
silence
"I'll give you $40 for the lot" says I
silence
"fine... hold onto it for another 30 years" I say

Then he starts putting the whole thing back together

....after another 10 minutes of childish exchange I start to walk away and he calls me back and we agree on $75 for the whole wheel.

I ended up with working drive flange, plus a spare hub, rim, cush rubbers and bearing retainer... all of which I don't need....  and he got lucky and made $75.

To be honest I would have spent more than that at a machine shop plus the arse of driving around town for the next couple of weeks so I'm generally happy with the outcome.  I had a number of breakers contact me to say they had spare flanges but they were all worn just like mine so I was running out of options.

Anyways... pictures below... all fits perfect and no more sprocket wobble...

LOL, ok this may be the post of the decade.  I had a good chuckle reading this one.

Just now catching up on this build but thank you very much for the documentation you're doing in your thread, Puffin.  I'm just at the point of reassembling the wheels on the 500 I'm working on and your build thread is going to come in very handy for me.  Well done.

Ron
 
Ron

Stella - Logan's Senior Project    78 750K http://forums.sohc4.net/index.php?topic=141761.0

Logan's Reward - CB500 and CB550 Cafes    http://forums.sohc4.net/index.php/topic,147787.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #113 on: October 06, 2015, 01:42:22 PM »
Quote from: Restoration Fan link=topic=145835.msg1736903#msg1736903 date=1444131117[/quote
LOL, ok this may be the post of the decade.  I had a good chuckle reading this one.

Just now catching up on this build but thank you very much for the documentation you're doing in your thread, Puffin.  I'm just at the point of reassembling the wheels on the 500 I'm working on and your build thread is going to come in very handy for me.  Well done.

Ron

Thanks Ron.... and thank you as well    I spent so much time going through build threads, including your 750 thread, before I even started this project.  I'm not sure I would have had the confidence to start this without having access to other peoples experiences and advice.

I'm looking forward to seeing how your 500 & 550's turn out and good luck with your wheel assembly... I spent more time on that bloody wheel than I did rebuilding the whole engine???
Honda CB500 four
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1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #114 on: October 08, 2015, 07:15:31 PM »
Installed new Stainless Steel brake lines up front.. 

If you want to keep the hard-line between the caliper and the lower hose for the authentic look don't forget that you need to get an adapter as the thread gauge is different.  It hides just behind the rubber grommet so you don't really see it.

New banjo bolts and copper washers installed as well
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #115 on: October 08, 2015, 07:29:32 PM »
Started back on the electrics.  Seems like a lot of people don't like this part but it's probably one of my favorites. 

I guess I find electrics logical rather than creative and that suits my personality... I'll fret and worry over a creative choice for ages but something like this I get stuck in with enthusiasm.

If you go back to the start of this build log you'll see I have already rebuilt the harness - it just needs wrapping but I'll be waiting until I have everything on the bike ready so I know for sure the length of all the wires around the rear of the bike.  As yet i haven't finalised the rear set up so i don't know where the rear indicators and tail light are going to be.

I replaced the original Regulator and Rectifier with a Combo unit that was pretty much plug-n-play.  I think it was a 'Ricks Electrical' unit.  i mounted it straight to the original electrical plate behind the left side cover.  It will get plenty of air there to keep cool.
Honda CB500 four
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1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #116 on: October 08, 2015, 07:31:06 PM »
Managed to find a new loom complete with bulbs and rubbers the Idiot lights.... 
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #117 on: October 08, 2015, 07:44:33 PM »
Mounted my Dyna Coils coupled to new spark plugs and NGK caps..   I also have a new Dyna electronic ignition to replace the points and a new Motobatt Battery to go in.

These are basic modern upgrades that suit my needs, budget and how I'll be using the bike... you can go a lot further of course but I think these offer the best bang for buck, reliability and performance increases to suit my machine.



Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline RAFster122s

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Re: 1972 CB500 - Rebuild Project
« Reply #118 on: October 08, 2015, 11:11:22 PM »
Apply a ring of JB Weld epoxy to the neck of the tank to keep the gas from getting beneath the paint and ruining the paint on the tank.
 
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #119 on: October 10, 2015, 05:32:56 PM »
Apply a ring of JB Weld epoxy to the neck of the tank to keep the gas from getting beneath the paint and ruining the paint on the tank.
 

Good tip thanks.. I was wondering about how to stop the gas getting under the paint.  Should have the tank back in a couple of days.

Puffin - 2 things: have you test fit your battery and side cover (or is the location different from stock?) with the Reg/Rec mounted sideways? Its a good location, I just don't seem to recall enough room there with the stock battery box in place.

And I can't tell from the coil pictures, just making sure your 2/3 coil has the BLK/WHT wire to the top screw as you have on 1/4. And I only ask because I can't see, even though I suspect you have it right... But I always ask to make sure on things like that.

1 - Yes have test fit and everything fits perfectly.  Everything is in the stock position.  There is about a  5-10mm gap between the air-box and the Reg-Rectifier Unit. (see below)
2 - Double checked and BLK/WHT wire is on the top screw on both coils.

Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #120 on: October 10, 2015, 05:50:03 PM »
My new battery arrived...

Model# -  Motobatt MB12U

It's an AGM battery, it has multiple terminals and a set of terminal adaptors so you can mount your cables and accessories as you like.  It also has a small tray to increase the height if you need it.

I also bought a matching Motobatt "Little Boy" charger and maintainer which came with a quick-connector so you don't have to muck about if you need to charge your battery or story the bike for a while. 

It's pretty yellow but you can't see it behind the covers.
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #121 on: October 10, 2015, 05:59:55 PM »
So I have a couple of decisions to make regarding the airbox cover.

I have no seat and so I plan on making a new seatpan and then getting a seat made by an upholsterer.  With the stock airbox however I need to make sure there is enough room between the top of the airbox and the base of the seat so the bike can breathe.

The stock CB500 came with a lid that also acted as a tool tray but this sticks up higher than the frame which is going to be a problem.
Honda CB500 four
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Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #122 on: October 10, 2015, 06:03:44 PM »
For some reason I also have what I believe to be a CB550 airbox... the top of this is slightly different in that it has a metal lid with a rubber 'funnel' attachment that bolts to an extra couple of brackets inside the air box.

This also sits higher than the frame but the rubber funnel is removable.


Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #123 on: October 10, 2015, 06:13:40 PM »
I figured that I could use the 550 lid without the attachment which would effectively be the same as using the original tool tray because the openings are the same size and in the same position over the air filter. 

In theory this should effectively act the same as the stock set-up.   I'm going to have to tune the bike from scratch anyway so any slight changes due to this set up should be easily accounted for.

I'm going to find a piece of metal mesh like the original and rivet or epoxy it over the hole to keep out any larger pieces of debris.

I installed the 550 brackets, re-glued the foam seal and gave it a lick of paint.

I'd be interested to hear any thoughts about this idea.  The result is that the opening to the airbox now sits lower than the frame so there will be a gap between the airbox lid and my new seat pan to allow airflow.
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html

Offline Puffin

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Re: 1972 CB500 - Rebuild Project
« Reply #124 on: October 10, 2015, 06:16:05 PM »
Couple more pictures
Honda CB500 four
Honda CB350 four (under construction)

1972 Cb500 Rebuild Project - http://forums.sohc4.net/index.php/topic,145835.0.html