Author Topic: CB500 Engine Rebuuild (Read 5430 times)

brett_bike · « **on:** August 26, 2015, 08:16:25 PM »

Here we are again. It's been a while but I've been tinkering/riding my '73 CB500 for about 7 years now. I've had a handful of other CB's of various displacements and XS650's that I've owned over the years. This CB is my keeper. She has never let me down and it's an attention-getter wherever I go. I have done everything to her with the exception of opening up the engine.

Now has come the time that I attempt it. I'm going into the engine to take care of the leaky head gasket and the recurring tick that comes back after every valve adjustment. I have spoken with Mark (aka: Hondaman) about taking care of the valves, seals, punch out cylinders, etc. I've ordered this oversize piston set http://www.ebay.com/itm/141624288455 from cruzinimage on ebay. Got the Vesrah gasket set on the way and my engine tore down. I will do my best to update this with pics of the process.

Please take a look at the attached pics and give feedback on the rockers and camshaft. There are what appear to be chips on the cam and rockers on the 1 & 2 intake. I have a 77 CB550 donor engine that is apart and the cam and rockers seem to be in better shape with no chips (CB550 cam has not been measured however). Can someone confirm whether or not the cam can swap?

SOHC4 Cafe Racer Fan · « **Reply #1 on:** August 26, 2015, 08:53:47 PM »

Those particular rockers should be replaced. It's hard to see what is wear and what is shadow/oil on the camshaft/ If the 550 parts are clean, use the 550 camshaft or a 650 camshaft (if you can find one). You can pool together the rockers to assemble a clean complete set.

RAFster122s · « **Reply #2 on:** August 26, 2015, 11:19:57 PM »

Definitely need better rockers than what was shown. If you use 650 cam you are going to need to slso have the cam gear from the 650 and a 650 mechanical tach and cable. Or, you can plug the tach port and use an electronic tach.
650 cam may require a little "clearancing" in the 550 cover so it doesn't hit anything.
Definitely use proper procedures for cover installation to prevent valve damage.

If going with 650 cam it is nice to keep same rockers with same lobes so you don't have wear problems.

calj737 · « **Reply #3 on:** August 27, 2015, 05:28:20 AM »

A 550 cam and its rockers will swap in directly.

My advice is to keep the rocker paired with its original cam lobe when installing a used cam. Otherwise, spend the money and have your stock cam hardwelded and the rockers too by a company MegaCycle. It's not cheap, but it's a sure fire way to insure the longevity of the motor. Also, an adjustable cam sprocket is a nice feature for timing the cam to the crank for optimum ignition.

brett_bike · « **Reply #4 on:** August 27, 2015, 01:21:23 PM »

Thanks for the replys guys.

Use all the rockers and cam from the 550? I can do that. They all appear to be in good shape. Is there necessity to measure the cam lobes(?) or do they not really wear down?

I'll try to post pics of the 550 cam and rockers letter today.

calj737 · « **Reply #5 on:** August 27, 2015, 01:47:43 PM »

They do wear. Its always best to measure "used" parts to be sure they're in spec before building a motor and relying upon them.

RAFster122s · « **Reply #6 on:** August 27, 2015, 03:22:53 PM »

How do you measure the pads of rocker arms to determine wear?

brett_bike · « **Reply #7 on:** August 29, 2015, 11:23:43 AM »

Received a package from Japan today. Time to deliver to Hondaman and get busy getting this bike back together.

RAFster122s · « **Reply #8 on:** August 29, 2015, 06:31:23 PM »

Honda pistons or other manufacturer? Looks nice.
David

brett_bike · « **Reply #9 on:** August 29, 2015, 06:54:29 PM »

Cruzinimage from eBay. Read many good reviews about their pistons.

brett_bike · « **Reply #10 on:** August 30, 2015, 04:00:00 PM »

Just got home from Hondaman's house. I dropped the parts and we discussed the process. He is a wealth of knowledge. Looking forward to getting the 500 back together. I gather from all the work that we're doing that it should ride like the day it came off the line.

I plan on posting pics of the reassembly process so I can keep track of my work and possibly inspire others that might be intimidated about tearing into thee machines.

Feed back, warnings and criticism encouraged.

brett_bike · « **Reply #11 on:** August 30, 2015, 08:10:09 PM »

Also, what are the thoughts of the group in regards on wether or not to replace the studs?

The bike has about 23,000 miles on it, and the studs don't appear to be rusty.

SOHC4 Cafe Racer Fan · « **Reply #12 on:** August 30, 2015, 08:20:54 PM »

I like to replace the stock studs with Heavy Duty studs -- either Cycle X/Kibblewhite or APE studs.

The stock studs can and usually stretch. The HD studs can be torqued more, which tends to help reduce gasket leaks. Removal of the stock studs, however, can be a PITA.

calj737 · « **Reply #13 on:** August 31, 2015, 05:13:11 AM »

all studs stretch. They're designed somewhat to do so. For a stock motor, and studs in good shape, Id leave them. I too like HD studs and nuts, but there's little cause to remove the stockers unless you're after more work.

brett_bike · « **Reply #14 on:** October 03, 2015, 07:59:47 PM »

Nothing to update. I'm waiting in head to come back from machine shop Hondaman and I discussing options to/not to replace all/some of the valve guides.

However, I did have a question regarding rockers. A few of my rockers were scratched and needed replaced. I have a donation 550 engine by I'm planning in using the rockers from, but there are a couple that are damaged also. My question is...is it ok to mix & match rockers form different engines. My bike is a 73 CB500 and the donation engine is a 76 CB550.

brett_bike · « **Reply #15 on:** October 07, 2015, 06:57:58 PM »

Calj737 mentioned in an earlier post to keep the rocker paired with the original cam lobe but a few of the rockers have nicks/gouges in them. Replacing just the damaged rockers with good ones from my original engine may be the only option.

Anybody see a problem with this?

calj737 · « **Reply #16 on:** October 07, 2015, 06:59:13 PM »

Better to replace than to use gouged units. Go for it-

brett_bike · « **Reply #17 on:** October 07, 2015, 08:45:25 PM »

Thanks Cal, I'm heading to the garage to swap them out.

Also, I picked up the cylinder and pistons from the machine shop today and I'm looking forward to getting the intakes back from Hondaman so I can slap this sucker back together. '

Luckily Denver has pretty decent weather well into November so I can get a few break in miles before we really get into winter.

brett_bike · « **Reply #18 on:** January 12, 2016, 09:11:22 AM »

So life has forced me to put this on the back burner until now. I had a spare 15 minutes today to install the Pistons and organize the other bits.

Any advice before I screw things up beyond repair would be greatly appreciated.

Sent from my iPhone using Tapatalk

brett_bike · « **Reply #19 on:** January 12, 2016, 09:15:08 AM »

Sent from my iPhone using Tapatalk

bochnak · « **Reply #20 on:** January 13, 2016, 06:07:44 AM »

Lookin' good!

GV1390 · « **Reply #21 on:** January 13, 2016, 06:43:32 AM »

Nice work!

SOHC4 Cafe Racer Fan · « **Reply #22 on:** January 13, 2016, 04:59:41 PM »

Quote from: GV1390 on January 13, 2016, 06:43:32 AM

Nice work!

That's a decent lift, too.

brett_bike · « **Reply #23 on:** February 18, 2016, 07:24:50 AM »

I finally had an opportunity to get in the garage for a few hours the other day and was able to get it put back together. I had to move quickly since I never really know how much time I'll be allowed by the Wifey so unfortunately I don't have pics of the process. But if I can follow instructions, anybody can. The 500 is really a strait forward build.

However, I do have one issue. My electric leg doesn't work. I can kick start it and all is well, but when I hit my start button I get clicks and I can hear a buzzing coming from my starter solenoid. My battery reads 12v and it increases to 15v when the rpm's increase so I think my battery still ok.

Thoughts?

Sent from my iPhone using Tapatalk

Denver_Larry · « **Reply #24 on:** February 18, 2016, 08:12:00 AM »

Where in Denver did you get your machine work done?

brett_bike · « **Reply #25 on:** February 18, 2016, 09:47:57 AM »

Hondaman sent it to some machine shop in Arvada, about 58th between and Wadsworth.

Sent from my iPhone using Tapatalk

Oakleyguy · « **Reply #26 on:** June 20, 2016, 11:39:23 AM »

~~Did the shop happen to be Ridge Reamer?~~

Ridge Reamer is the shop.

RAFster122s · « **Reply #27 on:** June 20, 2016, 01:37:27 PM »

Congrats on getting some time to put it back together!
Well, at least your switch side of the circuit is working on the starter, getting the buzzing solenoid. Have you rapped on the solenoid with a screw driver handle to see if it is sticking?
Check your voltage on the solenoid to see if you have battery voltage there and compare to your battery reading. Direct shorting the terminals on the solenoid, does that cause it to work correctly?

Thanks!
David

brett_bike · « **Reply #28 on:** June 20, 2016, 05:19:39 PM »

Thanks Raf

It seems as though when the battery is fully charged it fires up no problem. I think is allowing the battery to Norfolk recharge.

Another issue I'm having now is the pesky ticking that keeps coming back after adjust the valves. This happened before the rebuild so I'm on the search for a 550 cam cover. I'm pretty sure my lobes are wore and allowing the cam shaft (?) to wobble. I need a 550 cam cover that has the locking dowel pins.

If you have a lead please let me know.

RAFster122s · « **Reply #29 on:** June 21, 2016, 01:37:41 AM »

I wish I had one too Brett. Put a search on ebay to notify you of any '76 - '78 CB550 cam covers/valve covers/etc. to match the possible permutations and see if you can score one for an acceptable price. You don't want to ruin a set of rockers on a cover that has issues... Or, wipe out a good cam on one.
David

brett_bike · « **Reply #30 on:** July 10, 2016, 03:30:21 PM »

So I'm currently at a stand still until I find a new rocker cover. My current cover has out of spec rocker guides so I tore it down hoping to find a rocker cover from a 77-79 CB550 that has the locating pins.

I've had a couple leads but nothing has panned out yet. If anybody has a lead on the cover I need, please pint me in their direction.

brett_bike · « **Reply #31 on:** July 12, 2016, 10:42:23 AM »

I visited my local moto salvage yard today and dug up the holy grail of CB500/550 owners. A rocker cover with the locating pins.

News:

Author Topic: CB500 Engine Rebuuild (Read 5430 times)