Author Topic: 78 CB 550K motor rebuild (Read 62127 times)

AlekStooge · « **Reply #50 on:** October 04, 2016, 05:51:39 AM »

#14 goes on the outer cutch housing. #15 look like it was already in there you can see it in the first picture around the outside of the circlip, the spacer moves around a little bit in there and looks like I never removed it.

Good point Dave, I'll look on the transmission shaft.

DaveBarbier · « **Reply #51 on:** October 04, 2016, 06:53:07 AM »

Quote from: AlekStooge on October 04, 2016, 05:51:39 AM

#14 goes on the outer cutch housing. #15 look like it was already in there you can see it in the first picture around the outside of the circlip, the spacer moves around a little bit in there and looks like I never removed it.

Good point Dave, I'll look on the transmission shaft.

That's correct, so there isn't a problem...or am I missing something? Just put the clutch assembly on and the circlip (#18) holds it on the shaft.

AlekStooge · « **Reply #52 on:** October 04, 2016, 10:21:10 PM »

Didn't cross my mind that the clutch goes on a shaft, got caught up looking at schematics.

I'm guessing the pop it in the freezer and heat up trick will get this gear on the shaft?

Number 18 and 22.
http://www.cmsnl.com/honda-cb550k-1978-usa_model7222/partslist/E++15.html#results

DaveBarbier · « **Reply #53 on:** October 05, 2016, 04:19:24 AM »

Is your endgame a functioning motorcycle? Then don't go trying to force it on the KICKSTART SHAFT, haha.

I think you need to clear your mind with a whiskey and prostitute break.

DaveBarbier · « **Reply #54 on:** October 05, 2016, 04:27:18 AM »

Haha, I misunderstood your post. I didn't see the point where you switched topics.

Shouldn't need freezing, but you can't assemble it before installing in the case first.

AlekStooge · « **Reply #55 on:** October 05, 2016, 09:57:19 AM »

Yeah I'm not at that point yet of installing the clutch on the kickstart.

My question is does that gear get pushed all the way down to the middle of the shaft or because It won't budge at the point I have it at. So I froze it.

DaveBarbier · « **Reply #56 on:** October 05, 2016, 11:18:48 AM »

I don't think it required freezing, but did it help? I honestly forgot how I got it on.

AlekStooge · « **Reply #57 on:** October 05, 2016, 11:27:04 AM »

Nope, heated the shaft up for a good 5 in and froze the gear overnight, didn't slid anymore forward. I looked at you build thread and a couple youtube videos but can't find anything.

Look at the schematic it makes sense for it to be pushed all the way in.

DaveBarbier · « **Reply #58 on:** October 05, 2016, 12:19:33 PM »

Well you'd need to freeze the shaft to make it smaller and heat the gear to make it larger if anything, but I don't remember doing that.

I assume you can tell if it is keyed or slotted or had a flat making it only go on one way, but without me having it in my hand I can't help.

The only motor I have apart is my 650 but those don't have a kickstart, haha.

AlekStooge · « **Reply #59 on:** October 05, 2016, 12:29:48 PM »

It has a flat portion that number 20 fits perfectly on. Gear 18 is completely round and has no flat part that's why it gets stuck.

http://www.cmsnl.com/honda-cb550k-1978-usa_model7222/partslist/E++15.html#results

Cal, wouldn't you'd want to freeze the shaft to make it smaller and heat the gear to expand it? Like Dave said

DaveBarbier · « **Reply #60 on:** October 05, 2016, 02:03:39 PM »

No, I'm wrong and Cal is right, freeze both. Heating the gear would decrease the hole size.

The gear (#18) does go past the flat in the shaft and butts up against the part that rides in the case.

The gear not having that flat wouldn't prevent it from going past. There has to be a washer or ring with a flat that you're not seeing or something.

Post a couple clear pictures of both ends of that gear and the shaft without the gear on it, I'm really curious now.

AlekStooge · « **Reply #61 on:** October 05, 2016, 03:41:26 PM »

Froze both, with a decent amount of pressure went right in. Cal was right.

There is no washer, clip, spacer etc. before the gear. if you look at CMSNL there is one after.

Now what I don't understand is when heated metal expands and when cold contracts, as far as my metallurgical knowledge goes. Hence me thinking freeze the shaft and heat the gear. So the shaft gets smaller and the bore in the gear gets larger making it easier to slide past the partially flat portion on the shaft.

AlekStooge · « **Reply #62 on:** October 07, 2016, 07:41:25 PM »

Is mixing assembly lube brands bad? I have used Red Line and I'm afraid I'm going to run out so I bought some Federal Mogul.

DaveBarbier · « **Reply #63 on:** October 07, 2016, 08:05:16 PM »

Nah, that's fine. Though it would be funny if combined and heat is applied it formed sand, haha.

AlekStooge · « **Reply #64 on:** October 07, 2016, 10:55:58 PM »

Not funny Dave

DaveBarbier · « **Reply #65 on:** October 08, 2016, 04:21:09 AM »

Yeah, like some amazing undiscovered two part epoxy. That would benefit the forum Alek, take one for the team.

AlekStooge · « **Reply #66 on:** October 08, 2016, 06:17:48 AM »

Not funny, I'm pulling my hair out here and you guys are kicking back your chairs and rolling around and laughing.

AlekStooge · « **Reply #67 on:** October 08, 2016, 08:01:09 PM »

Alright I tired a JIS screwdriver, PB Blaster, impact screwdriver, propane torch, heat gun, screw extractors, and chiseling I can't remove any of the screws on the oil pup cover so I can replace the O ring inside. I'm out of ideas.

Is it just me or am I having more trouble than most with stick fasteners on my motor. I mean these screws aren't even torqued that tight.

NobleHops · « **Reply #68 on:** October 08, 2016, 10:46:02 PM »

If those divots are well centered, next step is to drill with larger and larger sized bits till you get the screw head all the way gone. Pick it out when you bust through and have just a ring left. Do all three, remove the cover, then see if the stubs turn out easily with pliers. If not, repeat the heat and penetrants till they do.

These things break your balls sometimes.

AlekStooge · « **Reply #69 on:** October 09, 2016, 05:19:04 AM »

That what I felt like I have been doing. let me try again.

I already have the rebuild kit.

AlekStooge · « **Reply #70 on:** October 09, 2016, 11:56:32 AM »

I tried again for a couple of hours. I tried using both larger and smaller bits and extractors. I can't get the heads to break off. Maybe I'm not understanding something you guys are explaining to me. I drill counterclockwise into the center of the screw and push my drill with as much downward pressure as I can.

Here is my progress and the largest extractor I've used.

MRieck · « **Reply #71 on:** October 09, 2016, 12:05:48 PM »

Forget the extractors Alek. Use a drill bit that will basically remove the head of the screw. I have done it many, many times. Once the head is removed you can drill a small hole and use the extractor or use a left hand drill bit. Removing the head relieves the pressure on the threads.

AlekStooge · « **Reply #72 on:** October 09, 2016, 12:37:24 PM »

So keep going up in bit sizes till the head breaks off?

DaveBarbier · « **Reply #73 on:** October 09, 2016, 01:52:47 PM »

Wait, you're drilling counterclockwise? With a normal bit? No wonder you're not making progress. Drill clockwise...like you're drilling a...hole

Drill the screw until the head comes off, easy peasy. By the way, that bit is toast.

And to Cal's earlier point, since these screws are recessed, don't use a bit as large as the head or you'll be drilling into the oil pump body. Use a bit as large as the shank of the screw at the most. You can see what I mean in the picture.

AlekStooge · « **Reply #74 on:** October 09, 2016, 02:10:36 PM »

I think I drilled to the oil pump body a long time ago. I'm drilling clockwise. The head is not coming off. Not easy peasy. I keep moving up in bit sizes nothing changes, I'm at a fairly large bit size. I've been drilling about two hours now, did more before that too.

At least tell me if I'm making any progress.

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Author Topic: 78 CB 550K motor rebuild (Read 62127 times)