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Author Topic: 76 CB550 Cafe build  (Read 94610 times)

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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #125 on: July 10, 2017, 07:40:19 AM »
When Honda lists an oring size are they giving outer diameter and thickness or inner?  This is in regards to the rear wheel o-ring mentioned above.  I can't find the original product without paying $25 shipping from europe, but I can get orings in whatever size I want.
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #126 on: July 10, 2017, 10:32:04 AM »
vcyclenuts offers a nice service where all you need to do is mail in your ECU and they will reflash and send it back (or even core exchange it).
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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
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"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)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #127 on: July 10, 2017, 10:42:40 AM »
Yeah, the mail it/flash it/mail it back is what I had done.
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Offline Godffery

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Re: 76 CB550 Cafe build
« Reply #128 on: July 10, 2017, 02:38:26 PM »
Quote from: tshrey on July 10, 2017, 07:40:19 AM
When Honda lists an oring size are they giving outer diameter and thickness or inner?  This is in regards to the rear wheel o-ring mentioned above.  I can't find the original product without paying $25 shipping from europe, but I can get orings in whatever size I want.
I can hook you up with one of those rear wheel o-rings and I'm in the US.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #129 on: July 10, 2017, 05:28:13 PM »
How does one order from you?
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Offline Godffery

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Re: 76 CB550 Cafe build
« Reply #130 on: July 11, 2017, 08:08:31 AM »
Quote from: tshrey on July 10, 2017, 05:28:13 PM
How does one order from you?
You can email me directly at jstephens7@wi.rr.com.
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Offline spatrucco

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Re: 76 CB550 Cafe build
« Reply #131 on: July 19, 2017, 04:42:57 PM »
Hi, are you willing to sell the original exhaust?
I'm interested in the the number 4 pipe.
Thanks

S.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #132 on: July 19, 2017, 04:49:04 PM »
The pipes were rotted away to nothing inside the covers. They were the first thing to get binned.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #133 on: August 30, 2017, 11:31:21 AM »
Quote from: cantarauk on May 29, 2017, 10:24:33 AM
Hi Tshrey,

Here are all the components and bearings pulled from my rear hub for your reference. These are from a cb500 but should be the same as 550.

. 


I'm going to turn the spacers out of a single piece of aluminum.  If anyone has a set of these free can you measure the end to end length of the two pieces put together?
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #134 on: September 07, 2017, 07:15:27 AM »


After I get the garage rearranged I'll be ready to go to town!
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #135 on: September 11, 2017, 08:29:50 AM »
Rear axle spacers all done in aluminum.  The outer spacers will get powdercoated.  Stock steel vs aluminum.



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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #136 on: September 13, 2017, 09:01:15 AM »
Installed the inner spacer and new wheel bearings from all balls and laced up and trued the wheel.  The inner spacer is exactly (within 1 thousandth) the same size as the stock pieces put together, but when I pounded the bearings in flush to the outer race lip things are so snug I can barely turn the inner races by hand.  I'm guessing they should be free turning, no?  Not sure why I'm running into this unless the all balls center races are a tiny bit thicker than stock - they certainly stick out more than the outer races.  Any suggestions?
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #137 on: September 29, 2017, 03:50:09 PM »



Finally a little progress.  592 pistons installed on rods.  Setting the ring gap was a little strange, Dynoman's directions call for .010 on the top ring and .011 on the second.  I had to file open all the tops a couple thousandths, but all of the second rings were already gapped at .015.  Contacted them and they said to get it as close to what they recommend as I could so I just let the second rings alone.

Also turned an aluminum insert with an o-ring to close up the hole where the starter went.  Have to cut it down a bit and drill a hold for the hold down screw that I tapped into the engine case.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #138 on: October 05, 2017, 10:14:26 AM »
Got the cylinder sleeves on.  Not as trivial as I expected, one of the pistons kept wanting to get crooked just past the oil rings and I though the rings themselves were holding things up.  Didn't think about the bottom gasket sticking out, that green looks pretty ridiculous...


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Offline RAFster122s

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Re: 76 CB550 Cafe build
« Reply #139 on: October 07, 2017, 04:40:09 PM »
You will need to back out that bearing...
Hopefully this can be done without destroying a bearing but...probably not.
The bearings are likely thicker.  Yes they should have some free turning to them. If you do them like Honda recommends there is a bit of side loading on the race and this will wear out the bearing prematurely. (According to HondaMan, I once read where he shared that wisdom).
The spacers should engages the inner races only, not the outer races... This is likely not an issue since they are identical to stock.

I am surprised the outer races are not a bit larger than stock.  Maybe Honda sourced some that were spot on. Often I've seen a few just a bit wider on some new bearings than the stock Honda. It only bites you on these kinds of applications for wheels.

Good luck sorting it out.
Very nice work.

That is a very nice Mill. how much did something like that go for and where did you find it?  Did you have to refurbish it/rebuild it or was it in great shape and ready to go.  That will be so handy for lots of things if you tinker with things like I do.

I once had a part made by a guy who had a mill and metal lathe in his workshop. Apparently he was a machinist his whole life. I took him a measured drawing of what I wanted made and the rubber insert and he machined up a nice part for me...taking into account the tolerances and use of the cup.
Was a starter cup using a readily available Miller brand starter insert, I was making a 1/2A engine (0.09 to 0.020) sized electric starter using a RC Car motor.  Turned out nice.
Rarely used on the 0.020 which is actually a 1/4A size.

Very nice looking motor and pistons.  Little bike porn...
You going to use a GPS equipped speedometer/tach unit?  Then put a plug in the camshaft cover?

Green gasket, should be able to paint it with black paint before it goes in the motor with a fine brush... I don't think I would risk cutting through the powder-coating using a hobby knife. A scalpel is far sharper than a hobby knife you do want to trim it, but you will still see the green line.

David
« Last Edit: October 07, 2017, 04:42:33 PM by RAF122S »
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Offline RAFster122s

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Re: 76 CB550 Cafe build
« Reply #140 on: October 07, 2017, 04:43:42 PM »
ARP fasteners...you've been watching Cal and drinking his koolaid I see...  ;D :D  NICE
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #141 on: October 07, 2017, 08:21:20 PM »
Got the bearing sorted.  Found another thread where someone talks about how the bearing stack works on the rear wheel.  The side with the threaded retainer is supposed to be seated in the wheel, the other side is supposed to 'float'.  The sleeve for that bearing is pretty damn snug, not sure how much floating that side will do.  Anyway, I put the axle spacer and the axle on the retained side and gave it two whacks with a hammer while I held the wheel suspended.  That was all it took, both inner races turn freely.  It was probably only tight by half a thousandth.

You don't even want to know what I paid for the bridgemill :)  Had a friend who started a business out of his one car garage and needed it gone.  Gave him $300 for it.  I'm getting pretty good using it, also have a four jaw chuck for precision work.  Plan on a motogadget Chronoclassic flushed into the headlight bucket and a digital speedo off a magnet on the rotor.  Already turned the plug for the camshaft...


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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #142 on: October 26, 2017, 07:02:00 PM »
These wheels are going to be the end of me.  Got the rim tape all done, had the tires mounted and balanced and after a day they were flat.  Marked the tire so I could maintain balance and removed them.  Let me tell you, taking a 100/90R18 tire off a 2.15 rim is a real #$%*.  After they were removed I could see that when they threw the tire on the machine it drove the bead down so far it peeled the edge of the tape off.  So I retaped it with 3m 4411 tape instead of the 4412 - it is about half the thickness and a lot easier to work with.  Remounted front tire and got the bead set.  Remounted rear tire and the bead wasn't even close enough to use air, had to pull out the ratcheting tie down trick.  Anyway, the bead is mostly set but about a 9" section of the tire is still stuck down in the groove.  It seals enough that it holds air and you can hear the bubbles screaming when you spray windex on it.  My question is, how high in air pressure can I go to try to make this bead pop into the seat?  I'm at 70 psi, bouncing the tire on the ground, everything I can and it doesn't move.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #143 on: October 27, 2017, 12:55:52 PM »
Had an epiphany over lunch.  What is the slickest water-soluble thing you can think of?  Put KY on the tire bead that wasn't sealing, same hit of air at 70 psi and it popped right into place :)
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Offline RAFster122s

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Re: 76 CB550 Cafe build
« Reply #144 on: October 28, 2017, 02:31:59 AM »
Girlfriend or wife may not believe any explanation you might give as to why you have KY Jelly in your toolbox/tool. Thanks            David
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Offline SOHC4 Cafe Racer Fan

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Re: 76 CB550 Cafe build
« Reply #145 on: October 28, 2017, 03:37:25 PM »
Lots of reasons to have it in your tool box, I suppose if you're into that.
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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
2015 Yamaha FZ-09 (http://forums.sohc4.net/index.php/topic,186861.0.html)

"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)

Sold/Emeritus
1973 CB750K2 "Bionic Mongrel" (http://forums.sohc4.net/index.php?topic=132734.0) - Sold
1977 CB750K7 "Nine Lives" Restomod (http://forums.sohc4.net/index.php?topic=50490.0) - Sold
2005 RVT1000RR RC51-SP2 "El Diablo" - Sold
2016+ Triumph Thruxton 1200 R (http://forums.sohc4.net/index.php/topic,170198.0.html) - Sold

Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #146 on: October 29, 2017, 02:41:56 PM »
You guys are all hilarious.  The KY was not in the toolbox (at least not the toolbox in the garage).

Mocking stuff up and simultaneously getting the welder ready for the rear hoop and cleaning up the tank.



Once the hoop is on I'm going to start serious work on getting the tail done.  It will be a standard cafe tail, flat seat section that kicks up in the back.  Will be black leather along the sides and the top surface will be black alcantara with a red diamond stitch.  The color we've settled on is from a Jeep...



Have to mock up a headlight and see what size I want to go with.  Definitely doing an LED headlight.
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #147 on: November 06, 2017, 06:34:07 AM »
I have the tank down to bare metal, ready to start dent repair.  Any hints on removing the cap and locking hardware? 
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #148 on: November 06, 2017, 06:44:20 AM »
Thank you.

What you describe is on the cap side.  What about the latch side?  There is a small philips head screw, but that just turns.  On the far side is a little 'door' that is held in place with a pin - does that just get ground off to expose something behind the door?
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Offline tshrey

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Re: 76 CB550 Cafe build
« Reply #149 on: November 06, 2017, 06:46:47 AM »
Nevermind Cal, just found a pic of a new assembly.  That little pin holding the door on looks like the tip of a screw that goes through the whole assembly.  I just I need to keep turning that screw :)
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