Topic: Wolfey's 1976 CB550 Street/Track Build

[Wolfey]

Hey everyone. I figured its time to create a thread on my build. I bought this bike a year and a half ago July 2014 not running. They previous owner threw the chain and blew out the neutral switch assembly and didnt know how to repair it. Well I got it home, grounded the neutral switch to the case and jumped it with a battery charger. 15 minutes later I had a running CB550K in decent condition. Here is a few picks of that day.





Well I rode it in this condition for the rest of the summer before my Friend Mel Chiro and I decided to tear it down and build a street/track 550 that is a hybrid of old and modern.

First came the tear down.


Getting the engine out was and absolute pain!!! I ended up laying the bike on the side and having to lift the frame off upside down to get it out.




Next the engine went to the shop for a big bore (603cc) and decked the head .006". While that was being done we decided that we where going to detab the frame and put a few braces in.





One of the things we noticed while taking apart the bike is that one of the previous owners had dumped it on the right side and blew out the whole side of the case. Instead of replacing it they welded it all back together and welded the case together in the process.



We had to cut the case with a grinder to get it open.




The new case looked to be in good condition. It looked like they maybe had siezed a bearing and threw a connecting rod.



More to come later tonight..... with pics.

[calj737]

The easiest way to remove/install the engine is to lay the bike on the right side, pads beneath the motor, then lift the frame off. Upside down sounds a bit unorthodox. Removing the oil pan helps too but its not required.

[Wolfey]

Yep thats how I tried to do it, but it was having clearance issues. Probably removing the pan would have helped. The end solution was to have it on its side and stand the bike upside down off the motor. 

[SOHC4 Cafe Racer Fan]

Interested to see where you go with this. 

Welding a case together?! What the heck was the PO thinking!? 

[Wolfey]

Next I wanted to update the front end so I found a 2004 GSXR1000 front end for a good price. I also wanted to add better tires and rims for racing so I went with the jixxer wheel up front and a SV650 rim in the back to accomodate the 160/17 tire I wanted.


Unfortunately the rim didn't fit and align correctly in the stock swing arm. We did figure out that we could flip the swing arm and get the alignment to work.




Basically this is where I am now on the bike. I have a rolling frame and now slowly been collecting parts lately for a big push to get the bike more together.

Couple other images....

Did some custom plates for rear sets.


Think I am going with this for rear lights. Just need to build a bracket to mount it. Been waiting to get my custom seat so I have that for placement.


How the front end will look.


My instrument guage I am using.


Bike with the new rear shocks on it. Need to finish the mounts though.


This week I received the Seat and a new 5 3/4" Headlight bucket with shock tower side mount brackets. More pics this weekend when I get a chance to start mocking them up to mount and build brackets.

[Retro Rocket]

I don't get how flipping the arm aligned the wheel, it could just be the pics but the wheel now looks offset to the right....?  The chain line is out with the swingarm in the normal position, the easiest way to fix that is to machine down the sprocket carrier... Is that a 4.5 x 17 inch rear rim..?

[Wolfey]

It is a 4.5/17 rim. The way the rim sat in the swing arm right side up it was offset to the frame. Flipping the swing arm with the SV650 rim aligned it to the frame.


Probably could have had the sprocket carrier machined down but this fixed it without any machining needed.

[seanbarney41]

Race it?...what sanctioning body has a class for such modifications?

[Wolfey]

No racing, just track days. I have a group of friends that appreciate air cooled bikes. they build and track them during the summer in the Pacific Northwest. Most of them do the DOHC 750s, 1100s, and CBXs. I love the SOHCs and found this 550 and thought it would be the perfect bike to build.

[Retro Rocket]

It is a 4.5/17 rim. The way the rim sat in the swing arm right side up it was offset to the frame. Flipping the swing arm with the SV650 rim aligned it to the frame.


Probably could have had the sprocket carrier machined down but this fixed it without any machining needed.

Interesting, machining the carrier is a hell of a lot less work that what you've done, you mean the spacers didn't line the wheel up ?, they are easy to fix too..?  You'll will still have problems with chain line if that wheel is centered, the Suzuki carrier sits out a lot further than the honda one, even a 10mm offset front sprocket isn't enough to line the chain up properly.... I have already done a 4.5 inch Suzuki rim into a Honda swingarm, it was relatively easy...

[SOHC4 Cafe Racer Fan]

No racing, just track days. I have a group of friends that appreciate air cooled bikes. they build and track them during the summer in the Pacific Northwest. Most of them do the DOHC 750s, 1100s, and CBXs. I love the SOHCs and found this 550 and thought it would be the perfect bike to build.

Cretins Seattle?

[Wolfey]

It is a 4.5/17 rim. The way the rim sat in the swing arm right side up it was offset to the frame. Flipping the swing arm with the SV650 rim aligned it to the frame.


Probably could have had the sprocket carrier machined down but this fixed it without any machining needed.

Interesting, machining the carrier is a hell of a lot less work that what you've done, you mean the spacers didn't line the wheel up ?, they are easy to fix too..?  You'll will still have problems with chain line if that wheel is centered, the Suzuki carrier sits out a lot further than the honda one, even a 10mm offset front sprocket isn't enough to line the chain up properly.... I have already done a 4.5 inch Suzuki rim into a Honda swingarm, it was relatively easy...

Interesting. Right now we are just doing mock up/build up. We were kinda waiting to get the engine back and get that back together to figure out the front sprocket. With the swing arm right side up there was no spacer on one side and all on the other plus because I went with a 160/17 (if I would have done a 140/17 I wouldnt have had any of these problems, I like a challenge though  ) tire there was rubbing issues. By flipping the swing arm, we got spacers on both sides, the tire to line up to the frame and the tire to not rub on the swing arm.

Possibly when we get the engine in the frame it sounds like from you we will still have to machining the carrier to get our chain to line up properly. Even if this has to be done there wont be rubbing issues like there would have been with the stock swing arm right side up.

[Wolfey]

No racing, just track days. I have a group of friends that appreciate air cooled bikes. they build and track them during the summer in the Pacific Northwest. Most of them do the DOHC 750s, 1100s, and CBXs. I love the SOHCs and found this 550 and thought it would be the perfect bike to build.

Cretins Seattle?

No. Some nice looking bikes they have though.

[seanbarney41]

No racing, just track days. I have a group of friends that appreciate air cooled bikes. they build and track them during the summer in the Pacific Northwest. Most of them do the DOHC 750s, 1100s, and CBXs. I love the SOHCs and found this 550 and thought it would be the perfect bike to build.

sounds very fun...wish their were similar heads in my neck of the woods

[Retro Rocket]

I still can't work out the rubbing issues..?  That pic i posted is a 180 slick on a 4.5 inch rim, no rubbing when centered correctly, It is a 750 arm but they bolt straight into the 500/550 anyway, others here have fitted rims like that without the problems you say you are experiencing..  Look for Rustyolives 550, he has a 5.5 inch rear rim in a stock arm if my memory serves right...

EDIT, looks like RO made a new swingarm to run the 18x5.5 inch rear rim. I'll post the thread for you anyway...

Rusty's bike...



Rusty's build thread...

http://forums.sohc4.net/index.php/topic,81683.0.html

[Wolfey]

I still can't work out the rubbing issues..?  That pic i posted is a 180 slick on a 4.5 inch rim, no rubbing when centered correctly, It is a 750 arm but they bolt straight into the 500/550 anyway, others here have fitted rims like that without the problems you say you are experiencing..  Look for Rustyolives 550, he has a 5.5 inch rear rim in a stock arm if my memory serves right...

EDIT, looks like RO made a new swingarm to run the 18x5.5 inch rear rim. I'll post the thread for you anyway...

Rusty's bike...



Rusty's build thread...

http://forums.sohc4.net/index.php/topic,81683.0.html

That's a nice bike. I will have to read that post tonight  If I would have went with a 750 arm I wouldn't have had issues. I had two choices: To try and make the stock arm work or make one. We figured trying to make it work would be fun to try. I will take closer pics this weekend when I play with the bike unless my friend posts some.

[calj737]

I'm with Retro, the stock 550 arm will easily accommodate a 160 tire, but you will need a front drive sprocket with some offset, despite what you do at the rear. The chain will rub the tire because the sprocket is well inside the frame line. The 550 arm is longer than the 750 arm, and in fact, wider nearer the axle line. But it doesn't really matter now about its orientation since you've adapted and fabricated a solution for suspension. But do expect to still have some machining/alignment work left once the cases are in place.

You can check out CognitoMoto's (among many, many others) running a 160/17 on a stock 550 arm.

[Wolfey]

Worked on the bike some more today. Got the whole front end mounted and put where I want it.





Also worked on getting the rear light and the seat mounted. With the seat I picked I needed to cut part of the rear off. It worked out really well because I was able to mount a bracket to hold the light perfectly under the seat.






Loving the seat. I think the brown is going to look awesome with a fresh new coat of that green on the tank.

[Retro Rocket]

Do you realize that the guard mount you removed from the rear of that bike actually stabilizes the rear suspension by removing flex...? 
I'd be reinforcing that somehow...

[calj737]

Do you realize that the guard mount you removed from the rear of that bike actually stabilizes the rear suspension by removing flex...? 
I'd be reinforcing that somehow...

Tying the ends together should have solved that mostly, Retro. With no passenger seating/weight, the forward flange does most of the bonding of the seat rails, and his flat stock tied across should see him do alright. I just hope he replaces the stock P.O.S shocks to support the front end changes. 

[Wolfey]

Do you realize that the guard mount you removed from the rear of that bike actually stabilizes the rear suspension by removing flex...? 
I'd be reinforcing that somehow...

Tying the ends together should have solved that mostly, Retro. With no passenger seating/weight, the forward flange does most of the bonding of the seat rails, and his flat stock tied across should see him do alright. I just hope he replaces the stock P.O.S shocks to support the front end changes. 

I am actually going to reweld the cross brace back on in some fashion for mounting to the seat too. So there will be more cross stability also.

Hahaha yes I have new shocks I just put the old ones on because I didnt want to cut/weld around the new ones!

[SOHC4 Cafe Racer Fan]

With the Suzuki triple tree branding, you got yourself a Honduki.

What shocks are you planning to use?

[Wolfey]

With the Suzuki triple tree branding, you got yourself a Honduki.

What shocks are you planning to use?

I do want to replace that badge with one of the Honda wing ones. 

I am using 340mm RFY air shocks with 485lb spring rate. Here is a pic of them mocked up.

[calj737]

 

[SOHC4 Cafe Racer Fan]

With the Suzuki triple tree branding, you got yourself a Honduki.

What shocks are you planning to use?

I do want to replace that badge with one of the Honda wing ones. 

I am using 340mm RFY air shocks with 485lb spring rate. Here is a pic of them mocked up.

I might be reading your post wrong, but are your shocks set up for a 485lb bike? If so, it will be over-sprung.  The stock 550 weighs 423 wet, and you've shaved some of that weight.  You may also want to check your fork springs when the build is complete, as the change in weight may warrant different springs.

Your speedo/tach instrument looks similar to a Koso, but I didn't see the model on their website.  Where did you source it?

[Wolfey]

With the Suzuki triple tree branding, you got yourself a Honduki.

What shocks are you planning to use?

I do want to replace that badge with one of the Honda wing ones. 

I am using 340mm RFY air shocks with 485lb spring rate. Here is a pic of them mocked up.

I might be reading your post wrong, but are your shocks set up for a 485lb bike? If so, it will be over-sprung.  The stock 550 weighs 423 wet, and you've shaved some of that weight.  You may also want to check your fork springs when the build is complete, as the change in weight may warrant different springs.

Your speedo/tach instrument looks similar to a Koso, but I didn't see the model on their website.  Where did you source it?

I will have to check on the shocks. They only have one rating on the springs. I havent personally tested them. They are much stiffer but I can get give out of them. I am leaning to they might just have them overrated and be rating them as a set, not individually. I did find this review of them. http://chrislivengood.net/wp/rfy-340mm-shock-analysis/ They state 140lbs per spring which seems much more realistic. The earlier information I just grabbed from the information the seller put on them. (They were an ebay purchase  ) ( They might have been posting the max spring rate too at full compression which would make sense on these since they are a variable rate spring.)

It is a Koso gauge. RX2N GP Style http://kosonorthamerica.com/product/rx-2n/ Its the BA015B15 Model.

[Wolfey]

Started working on my head porting it. I read the FAQ from Hondaman about creating the pocket above the intake valve, but I couldn't find anything more specific. So I found a few pics of other members on here and went to work. I think it turned out pretty nice! Only 3 more intakes some exhaust work to go....


Before photo:


The pocket area.


Before:

[Blackfin5]

Wolfey...you've really have me fascinated with this project.   Are you planning to stiffen the frame at all?

[sbeckman7]

This is getting good   What exactly are you doing with those intake "pockets"?  Hard to tell from the pics.

Spence

[Trad]

Are you going to rig up any kind of flow bench after you've finished the porting? Man, you are braver that I! haha. Project is looking sweet dude.

[Wolfey]

Wolfey...you've really have me fascinated with this project.   Are you planning to stiffen the frame at all?

I did quite a bit of stiffening to the frame. I braced the frame in the triangle where most of the torsion is. Also right below the air intakes I did a cross bar there as well to limit the torsion of the frame from side to side. I did the brace for the tail light ( 1/4" plate steel) that should help with torsion too. I am also putting a brace in the back for mounting of the back of the seat. Here are some pics to show the bracing.



This one shows the brace just under the front of the seat.

This one shows the cross frame brace where the intakes would be. (Sorry I dont have a better picture right now.

[Wolfey]

This is getting good   What exactly are you doing with those intake "pockets"?  Hard to tell from the pics.

Spence

Hi Spence,

So I was reading Hondaman's FAQ and he spoke about the flow of the heads in the 550. Here is the link http://forums.sohc4.net/index.php/topic,7401.0.html. So specifically in the section he wrote:

3. In the heads: all of the inline fours except the 400-4 had breathing issues. Grinding a "pocket" above the intake valve(s) and matching the ports to the carb tubes will improve them, especially at high RPM. Polishing the intake valve(s) helps, too. Don't back-cut the intake valves or you'll pop off a valve head - an expensive day, at best. (Backcutting exhaust valves will make them burn, and quickly - the CB650 malady). Trim (narrow) the intake valve guide bosses for a smaller profile, and polish it. Smooth, but don't polish, the intake tract. If you're good at heliarcing, raise a bead about .100" high along the bottom of the intake ports (CB750 only) in a half-moon shape, then smooth it off along the sides so it "restricts" (apparently) the bottom passageway about 1/3 of the way around. The floor of the port should ramp up to it, then be fairly abrupt in fall-off on the valve side. Do this at the point where the intake track bends down toward the valve (no, it's not easy). Although not obvious, this mod creates some "free turbocharging" at RPM above 6000, all the way to 16000 (lots of work), which deals more with fluid dynamics than I will put into this post.

So initially I am just doing a big bore on the engine. I will probably put it all together and just run it this summer as is. Then this next winter I am going to build the top end out quite a bit more with cam, valves, rockers, springs, etc. But to build up to all this I am trying to get the porting on the head done now to help with the response because I would like to track the bike this summer some. I am going to try and get dynos done at each stage too since I dont see many actual numbers and have the opportunity to do it.

Ernie

[Wolfey]

Are you going to rig up any kind of flow bench after you've finished the porting? Man, you are braver that I! haha. Project is looking sweet dude.

I hadn't planned on it. Maybe next winter when I build the motor out more.

Haha its only a head right? 

[sbeckman7]

Very cool (and interesting), thanks for sharing

[mrfish2]

I'm subscribing to this, interested to see how everything works out for you.

[FunJimmy]

My instrument guage I am using.

Interesting project. I really like the instrument cluster and welded cases.
One more than the other though.