Author Topic: 1974 CB 550 Build Thread - "Resto-mod"  (Read 13221 times)

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Offline Jeffro93

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1974 CB 550 Build Thread - "Resto-mod"
« on: December 06, 2015, 12:07:51 PM »
First, a quick introduction:  I'm Jeff.  I live in Fort Worth, TX and am at that middle-aged place in life where my kids are either out of the house or are very close, but they all need Dad's help (money).

I got into motorcycling late - about 7 years ago.  My first bike was an '83 Honda GL 650 that took three years to complete. Luckily, I decided to buy a 2003 SV650 after the first year of the build.  I sold it in about a year to buy a 2007 Honda VFR800, which I had for your years until I sold it this past spring.  I've still got the GL, and cosmetically redid a 2007 Bonneville last winter.  Two days after telling my wife that I wouldn't be tackling a winter project this year so that I could concentrate on other seemingly more important things, I found a '74 CB550 and here I am today - a complete and challenged man.

I got interested in CB550's several years ago at the Harvest Classic in Luckenbach, TX, where I ran into Steve-O and his band of merry SOHC4-ers.  We have been Harvest Classic neighbors repeatedly and a 550 has been at the top of my "next project" list ever since.

Here's a few pics of the GL and Bonneville.  The SV650 and VFR probably don't garner a lot of interest, here, and that's fine with me (they were great, but you'll notice that I no longer own them).

GL: Before


GL: During


GL: After



Triumph Before:


Triumph During:


Triumph After (At Distinguished Gentleman's Ride a few months ago):



I'm looking forward to sharing my progress with everyone and will have more than a few questions.  I've actually got the bike fully disassembled and have used the forum quite a bit looking for help, buying a few parts, getting ideas, etc.

Next post starts the build!
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Stev-o

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #1 on: December 06, 2015, 01:09:56 PM »
Hey Jeff...

Nice job on the Triumph, looks good.  Subscribed to see what you have in store for the CB.
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #2 on: December 06, 2015, 06:00:05 PM »
Alright.  Here's my 550.  For whatever reason, I decided to plug "barn find" in the Craigslist search bar and two days later, I owned this.  It came out of a kid's parents back yard in South Dallas, but he said it was his barn find.  According to the inspection sticker, it was last inspected in April of '86.  It's been off the road for a long time.  I don't think all of it was outdoors, but at least 6 or 8 years must have been.  It's got just over 20,000 miles on the clock.  The motor turned over and the vast majority of it was there (mostly missing airbag parts, which I have partially replaced already).  It even had a key. And a title.  It seems reasonable to me that the fairing and side cases indicate a non-abusive 13 years on the road.  Hard to say much about the level of maintenance that it received.

Right after purchase:




I took it to my storage unit for a month or so while I finished getting the GL650 ready for the Harvest Classic (which I ended up skipping due to some serious rain) and while I cleaned the garage up prior to starting a new project. I brought her home to introduce her to her siblings, but they promptly turned their backs to her:



Within about two weeks, I had it torn down and the engine out. 





My plan is essentially a restoration, but with a few modifications that could have been done in the 70's over the course of a weekend or two.  I don't expect to use period aftermarket parts, though.  Basically, I just plan to use Eurobars, a 4 into 2 or 4 into 1 exhaust (not loud, but not too quiet, either).  I'm currently considering the Delkevic 4 into 1, but I'm not positive.  I will repaint it a factory color, but I can't get too excited about "Boss Maroon Metallic", so I'm going with "Flake Sunrise Orange".  I've always more flaky than bossy, anyway.  Oh, and I may get a custom seat instead of stock and plan to use bobbed fenders (I've ordered some fiberglass ones to check out).  I won't be cutting the originals, though.  All original parts will stay with the bike in case I or the next owner decides to go back to completely stock.

So, I'm really at the start of this whole thing.  So far, the issues that I'm aware of are compression readings of 80-95 psi across all four cylinders, a very leaky shifter rod oil seal now that I've cleaned all the crud away, and some missing airbox parts (that whole air box is something of a mystery to me. The parts fiche is helpful, but really good pictures of all the parts and fasteners would be very helpful).

I'll be taking the frame, swing arm and several other parts to a local powder coater soon (after I get the pivot shaft out of the swing arm http://forums.sohc4.net/index.php/topic,153389.msg1753797.html#msg1753797.

I'm going to send the hubs and a few other parts to NobleHops soon for vapor blasting as well.

I'm looking forward to sharing the build and appreciate all the help that I'll be getting along the way.

Jeff
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline calj737

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #3 on: December 07, 2015, 09:07:46 AM »
make sure you heed the step to release the tension on the valves when you remove the valve cover form the engine. Also, if you don't yet own them, a good complete set of JIS bits for your toolbox will make your life much easier.

Maybe a modern interpretation of the Boss Maroon? Lots of Orange bikes out there...

As for the compression, don't fret. Very common to have low readings on a bike thats sat for some length of time. Once running, it may recover quite nicely. Also, the type of gauge effects the reading you get as well.
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #4 on: December 27, 2015, 09:04:19 AM »
Well, I've been a little busier than I'd hoped and progress has been slow.  Yesterday, though, I was finally able to make some headway. 

I had already planned to tear the engine down to the block, but I really don't want to open the case if I can avoid it.  I noticed last week that the plug threads were stripped on the #1 cylinder head, so I wanted to get a better look at that mess and start cleaning up the engine.

I'm sure my situation isn't all that unusual, but this engine was filthy!  I had done by my best to clean it before dismantling, but there are a lot of nooks and crannies for dirt dobbers, etc.  There was a LOT of crud around the head studs when I pulled the cylinder block off.  I very carefully wiped it off and away from the block openings with my finger, but I know that some got in when I was pulling the cylinder block off.  I'm not very excited about that.



When I finally got the cylinder head off, I realized that the thread situation may be a lot worse than I'd expected.  Either someone tried a helicoil that didn't work, or tried to drill and tap for a larger plug.  You can see the difference in the size of the hole by looking at the distance between the edge of the hole and the edge of the valve.  The first pic is #1, the second is #2 for comparison.

#1


#2


There's a shop close to where I work that works almost entirely on '60's and '70's Japanese bikes.  I'm going to take the cylinder head to him to see if he can help me, or if I need to start looking for a "new" cylinder head.

A few questions:

I'm thinking about sending the rocker cover, head and cylinder block to have it vapor blasted.  I haven't been able to find directions for removal of the rocker arms.  I would appreciate a little direction on that. 

Thanks.
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline calj737

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #5 on: December 27, 2015, 10:24:41 AM »
On the end of the cover, the rocker shafts are pushed in place. Use a 6mmx50mm bolt, screw it into the shaft, and pull the shaft out. Wriggle the rocker arm as you go.

The shafts are two from each end for the intake and exhaust sides, 8 total. To have your parts vapor blasted, they need to be decreased first, then send them to member Noblehops (Nils) for a professional job:
http://forums.sohc4.net/index.php/topic,150819.0.html
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline SOHC4 Cafe Racer Fan

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #6 on: December 27, 2015, 10:40:10 AM »
Welcome! 

You should request the moderator to move this to to
He project build board.
1975 CB550K1 "Blue" Stockish Restomod (http://forums.sohc4.net/index.php?topic=135005.0)
1975 CB550F1 frame/CB650 engine hybrid "The Hot Mess" (http://forums.sohc4.net/index.php/topic,150220.0.html)
2008 Triumph Thruxton (http://forums.sohc4.net/index.php/topic,190956.0.html)
2014 MV Agusta Brutale Dragster 800
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"There are some things nobody needs in this world, and a bright-red, hunch-back, warp-speed 900cc cafe racer is one of them — but I want one anyway, and on some days I actually believe I need one.... Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba." Hunter S. Thompson, Song of the Sausage Creature, Cycle World, March 1995.  (http://www.latexnet.org/~csmith/sausage.html and https://magazine.cycleworld.com/article/1995/3/1/song-of-the-sausage-creature)

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Offline Sox Fan

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #7 on: December 27, 2015, 04:55:48 PM »
Subscribed.

I am about to start a similar 74 CB550 project of my own. Nice looking Bonneville BTW. I also like the modern Triumph twins. Had an 05 Thruxton for a few years that I am missing. Might buy a carbureted T100 or Bonnie Black to play around with as well.

Offline FunJimmy

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #8 on: December 27, 2015, 08:07:44 PM »
Welcome to the site Jeff. Looks like you've got your winter work cut out for you.
I'd suggest finding a second cylinder head. They're relatively cheap compared to repairing.

Nice work out the GL and Bonnie.
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Offline Zaipai

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #9 on: December 27, 2015, 08:17:27 PM »
Welcome Jeff,
 Nice bike to start with..

Don't forget when you have time to post it on the 500/550 Registry here on the forums..

http://forums.sohc4.net/index.php/topic,29646.0.html

TTYS,
.: Scott :.
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75 CB550F  | 


Offline flatlander

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #10 on: December 28, 2015, 02:23:01 AM »
sounds like a good plan, will be nice to see what comes out of it.
i agree, getting a new cylinder head sounds easier than fixing the old one. also, for the rocker cover, try to find a 78 or later model (from a 550 k3 or f2) before putting too much work/money into it. the later ones have the rocker shafts locked down to prevent them from rotating and wearing out the cover itself.

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #11 on: December 28, 2015, 05:39:48 AM »
On the end of the cover, the rocker shafts are pushed in place. Use a 6mmx50mm bolt, screw it into the shaft, and pull the shaft out. Wriggle the rocker arm as you go.

The shafts are two from each end for the intake and exhaust sides, 8 total. To have your parts vapor blasted, they need to be decreased first, then send them to member Noblehops (Nils) for a professional job:
http://forums.sohc4.net/index.php/topic,150819.0.html

Thanks, calj737.  That sounds simple enough.  I've been watching Nils' thread for a while.  I'm setting parts aside to send to him soon.
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #12 on: December 28, 2015, 06:21:22 AM »
Since we're talking about the rocker cover/cylinder head, I've got a question:

When removing the rocker cover, I noticed that the locations of the screws and bolts were different from the Honda manual (I'll admit that the Honda manual diagram isn't very clear).  At first, I wondered if it had been previously removed and reinstalled incorrectly, but with the different lengths of the fasteners, I don't think that's the case.  The clincher for me was the four bolts beneath the breather cover; they appear to be screws on the Honda diagram.

I'm thinking that it's one of four things:
 1. The manual was early and there was a design change
 2. The bike is an early model - manufactured 7/73 - and there may have been a design change before the manual was published
 3. It was re-installed incorrectly in the past.
 4. I can't read the diagram and I'm wrong.

Does anyone have pictures of there rocker cover with the fastener's installed?

Honda diagram:


My rocker cover:
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline calj737

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #13 on: December 28, 2015, 06:27:01 AM »
the four fasteners you refer to are supposed to be hex flange bolts as stock.
'74 550 Build http://forums.sohc4.net/index.php?topic=126401.0
'73 500 Build http://forums.sohc4.net/index.php?topic=132935.0

"Of all tyrannies, a tyranny sincerely exercised for the good of it's victim may be the most oppressive. It may be better to live under robber barons than under omnipotent moral busybodies. The robber baron's cruelty may sometimes sleep, his cupidity may at some point be satiated, but those who torment us for our own good will torment us without end for they do so with the approval of their own conscience." - C.S. Lewis

Offline flatlander

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #14 on: December 28, 2015, 08:12:51 AM »
yours are correct, same as here on my '76 f1 cover:



for comparison, here's one of the later covers with the additional pins that keep the shafts from moving:


Offline Stev-o

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #15 on: December 30, 2015, 10:01:11 AM »
Hey Jeff.... I have a spare 550 head for you [free] if you want it, it has bent valves but you should be able to use your old ones.

The PO did not follow the proper procedure on reassembly and bent them, dont make that mistake!

The later head cover with the pins is a nice upgrade.

+1 on sending parts to Nils for vapor blasting, he did a great job on my H2 motor:



Ask him for the "Stev-o discount"...Ha!
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #16 on: December 30, 2015, 02:35:19 PM »
Thanks, Steve.  I should find out tomorrow if I need to take you up on your offer.  Is it the later model head?  Are the later heads the same other than the pins for the rocker arms?


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1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #17 on: December 30, 2015, 03:26:54 PM »
My previous comment was irrelevant with respect to the rocker arm pins...


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1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Lostboy Steve

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #18 on: January 01, 2016, 03:21:03 PM »
Welcome Jeff! My favorite band as of lately is from Fort Worth. Texans are always welcome. I have some family in Austin but I've never been to the state. Anyway, these little machines are as addicting as intervenes drugs.


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1968 Honda Z50
1977 Honda CB550K
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Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #19 on: January 03, 2016, 06:03:04 PM »
Time for a quick update and maybe a few questions.

The weather was nice today.  I almost rode, but then thought I'd fiddle with the engine for just a few minutes.  I never rode, but I did find a new problem...

I removed the pistons from the connecting rods and decided to clean them up a bit.  All went pretty well, but the #4 piston looks like it's seen better days.  As a reminder, the #4 cylinder is the same cylinder that has the stripped out plug threads in the head.  I cleaned up the combustion chamber for good old #4, and it was pretty beat up, too.  I'm not too worried about the head, since Steve-O will likely be sending a new one my way soon.  The question is, where's the best place to get a new set of pistons?  Technically, I probably only need one, but I may as well replace all four - I was planning to hone the cylinders and replaced the rings, anyway.

#4 Piston


#4 Combustion Chamber


Also, I think I've mentioned before that I would like to avoid opening the case and going through the bottom end - mostly because the gearbox makes me a little nervous.  I've been told that I should replace all oil seals on the bottom end while I've got the engine torn down to this level.  I already have a new seal for the shifter shaft, but I'm not sure what other seals that I need to get ahold of.

Thanks for your help, guys.

Jeff
1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Stev-o

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #20 on: January 03, 2016, 06:25:45 PM »
Hey Jeff.....It appears that #4 cylinder may have suffered a malfunction! 

You can buy cheap used pistons on ebay, I'd stick with Honda rings.  If your going to buy a new set of pistons, might be a good time to go big bore! [and install a 650 cam]

Yes, I have a head for you, can send it this week.  As mentioned earlier, this would be a good time to upgrade to the pinned head cover, I do not have a spare.
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline Jeffro93

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #21 on: January 03, 2016, 06:45:51 PM »
Thanks, Steve.  I've found a set of pistons already.  Based on price, I'm definitely going used.  I'll look into the newer head cover, too.  Do you know what year they started producing it?   


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1974 Honda CB550
1983 Honda GL650 Interstate "Cafe'd"
2007 Triumph Bonneville

Offline Stev-o

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #22 on: January 03, 2016, 07:17:03 PM »
Thanks, Steve.  I've found a set of pistons already.  Based on price, I'm definitely going used.  I'll look into the newer head cover, too.  Do you know what year they started producing it?   


I believe the '77's and '78's had the pinned head cover. Can someone confirm?
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline Trad

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #23 on: January 03, 2016, 09:22:16 PM »
Thanks, Steve.  I've found a set of pistons already.  Based on price, I'm definitely going used.  I'll look into the newer head cover, too.  Do you know what year they started producing it?   


I believe the '77's and '78's had the pinned head cover. Can someone confirm?

+1 77-78
74 CB550 Build: NOS-GUTTED-OEMplus-HOLDTRUE
http://forums.sohc4.net/index.php/topic,130575.0.html

Offline flatlander

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Re: 1974 CB 550 Build Thread - "Resto-mod"
« Reply #24 on: January 04, 2016, 09:05:52 AM »
yes, that's k3 and f2 models. also, in the parts list you see what engine numbers had the new type covers.
when buying have a picture sent to you (or inspect in person) as years can be misleading and covers may have been replaced on the same engine.