Topic: First Project Honda CB 550

[Awosborn]

Hello all,

I'm pretty new to the world of motorcycles. I started riding this spring on a vintage Harley that was originally built for my dad.I fell in love with life on two wheels and decided to dive in head over heels and build one. I figure if I'm going to ride on top of something that explodes thousands of times a second between my legs I might as well learn them inside out.

I was able to track down a 74 CB 550. It wasn't running after setting for the last year, dead battery and such. I know that goes against all good advice for buying a bike but I have a pretty full plan for it and the resources to see it through.

I've been sleeping 8 feet from the bike the last 3 weeks just walking around it during my morning coffee pondering ideas. So far the things I would like to accomplish are.

Knee dents in tank
Double disk front breaks
Open up air box/pods
Custom seat pan (hidden electronics) with under seat low profile LED brake and signal lights
Custom saddle (still looking for someone to that can make this)
Matching leather wrapped handle bars
Power-coated frame
Coated/enameled engine
New gauge setup
New exhaust set up?

I'm also open to performance improvements, I just frankly haven't done the research into that yet.

I know this seems extremely ambitious. However, I look at this project as an exercise in patience, a life skill set to be learned. I'm very excited to get started.
Here is where I ask you all for help.

I have spent the last several years traveling, owning nothing but what I carried on my back. I have no tool kit, no experience, only the yearning to learn. I hope this community can help guide me along the way. I have recently finished a large section of work and will have a lot of time the next three months to dedicate to this project.

Please share your ideas, thoughts and opinions.

You could all help me buy helping come up with a tool list so I can get started on the tear down. Please feel free to add to the list below or point me to specific brands/products. Ill purchase it all in the next few days after some feed back and get started.

So far I have come up with
metric wrenches 6-19mm
metric socket set
screw driver set with hex boosters
impact driver
rubber mallet (separate mallet to shape tank)
front/rear stands

Thank you all,

Alex

[SOHC4 Cafe Racer Fan]

Get the bike running safely and reliably first before tearing it apart.  Then you will have a better idea what needs to be addressed and could be (at the same time) customized or upgraded.

Download the Factory Service Manual (on this site) and do a 3,000 mile service -- to make sure all of your essential systems are working safely.  Also check the age of your tires and tubes (replace if over 7 years old) or if cracked. 

[Restoration Fan]

Welcome, Alex!  Great choice for your first build.
Excellent advice by Don.  I will likewise advise that you try to get it running first.  You may find that it doesn't need to be rebuilt or torn down but you will have a much better idea of what you have if you start with a running motor.

Post lots of pictures and questions.  Never be afraid to ask any question because you think it will make you look foolish.  I was in the same boat as you about 2 years ago and these guys walked my son & I through a rebuild of a 750 when neither of us knew diddly about working on a bike. And great choice on joining this forum.  You won't find a more welcoming, generous and knowledgeable group of guys anywhere.

Looking forward to seeing how this one progresses.

[flatlander]

i'm with the other guys: keep your ideas for modifications on the shelf until you know what you actually got there. first, get it running reliably and safely. don's advice re. manual and the 3k miles tune-up is spot on. while doing that you probably encounter a few things and will have some questions that people here can help you with. that will keep you busy for a while.
then use one season to ride the crap out of it. you'll find out then what it needs further, and your ideas for mods will be more refined after that.

[calj737]

A very important tool is a set of "JIS" bits or screwdrivers. The Phillips screws you see all over the bike are not Phillips, they're JIS (Japanese Industrial Standard). Even if you plan to swap them for socket head allens, you still need to extract them. Plus, your carbs won't be getting swapped hardware, so best you purchase a set.

You can buy a decent enough set of Craftsman tools of Metric components in a box that will take you 99% of the way.

Smashing in the tank for knee dents is a great deal trickier than you might think. Smash it too far and you'll split the welded seam or worse, crease the edges and have leaks. Getting it smooth, flush and elegant requires body filler afterwards. OR, you remove the shell, pound them in, finish them off with a planishing hammer, and then weld it back on. (Not exactly a DIY, Newb undertaking). You can buy aftermarket tanks in aluminum often with the body work done for you. That and a seat/pad.

Spend a bunch of time reading through the Projects section of different people's builds, ask questions, and discover their sources for parts and purchases. Its a great way to bend your learning curve. There's nothing you listed that hasn't been done by another member, so the experience you need and advice is freely available from folks here. And you will get heaps of offers for assistance and advice to help you avoid making costly mistakes. 

[SOHC4 Cafe Racer Fan]

There's nothing you listed that hasn't been done by another member

Yes, MessnerMoto has seen to that! 

[Awosborn]

Thanks guys I really appreciate the advice. Ill make sure to get a metric set of mechanical tools and a set of JIS screwdrivers on the way.

It sounds like the 3k checklist is the way to start. I'm a little hesitant to fill it all back up with fluids after draining but I respect the collective experience here.

I want to tear down to each individual component not necessarily because it needs done, but because I view this as a learning experience that just happens to reward me with a bike, less of a project in its self. I'm fortunate to run my own company and have set aside a lot of time in the coming months to work with this project, the chance of it making it to the summer without me starting to tear it apart is pretty slim.

I'll keep you all updated on what I find as a start into it, hopefully later this week. Keep the words of wisdom coming.

[Awosborn]

Tools are in, I've started to get things ready to go through the 3k service. The one thing I resisted buying was a battery at a local hardware store. I know that will serve to get things going but knowing I want to tuck it up under the seat I thought I might as well go ahead and buy what should serve me best in the end. I have done a bit of research but thought it wise to reference the collective knowledge.

I was looking at a Shorai LFX14A2-BS12 but have also thought the 8 cell Antigravity battery's were well reviewed. What do you guys think best?

P.S. Ill take care of the new member housekeeping after some work this afternoon. I see several of you area also based in Iowa City. If anyone is interested we should grab a beer.

[calj737]

Shorai.
That's all I'll say about that. 

[Awosborn]

Awesome. I'll plan on getting one of those on the way. Any reason to go with a different size?

[SOHC4 Cafe Racer Fan]

Antigravity can be touchy. If you have any glitch in your charging system I have seen examples of them runaway charging and bursting.  Make sure you are upgraded to a solid-state regulator-rectifier.

[calj737]

Awesome. I'll plan on getting one of those on the way. Any reason to go with a different size?

Nope, the model you referenced is perfect.

Regarding "touchy" AG batteries, I'm helping a member remotely with an M-Unit. He texted me yesterday AM with questions about why his bike runs for 5 seconds, then dies. Turns out, his battery only has 9.2v. Told him to charge it up and if needed get a new battery. His reply, "The AG 8 cell is brand new last week and now the vendor won't warranty the damn thing!".

So your query was rather timely in my experience.

[Awosborn]

Thanks very much for sharing!

[Awosborn]

Got the battery in last night and popped it in this morning. I have it in and have power running to all the signals and headlight.

I gave it a quick try at the electric start and the bike turned over but wouldn't fire. It did send a bit of gas down the overflow hoses from the bottom of the carb.

I plan on changing the oil and filters today and was wondering what the first steps you guys recommended to get the bike running as well as any traps (I.E. noob mistakes) to avoid. I'm currently hunting down a 18mm thin wall to pull the plugs, it may have to track down the local Snap On guy. They look new from above but that could be deceiving.

The bike was running a year ago according the the last owner. He just pulled the battery and put stable in the gas as he went to college and hasn't moved back to ride it before I bought it.

What are the steps I should take and, or things to avoid as I try to bring this bike back to life?

[flatlander]

did you already do the 3k maintenance mentioned earlier? if not: get busy!

the gas through the overflow tubes most likely came from stuck floats. if it stopped before you turned off the petcock then you're lucky and they un-stuck themselves. start with the 3k list but be prepared that the carbs may need cleaning, they usually do with bikes that stood a long time.

also, no matter what the PO said, the gas may be bad after a year of sitting. especially if it has ethanol in it. no need to dump it just yet, but keep it in mind as a possible reason if you have problems after you did the full 3k maintenance.

[Awosborn]

I'm working on it! . I've been on the road but I came home to a battery, tool kit and set of feeler gauges. I just got a filter and oil and plan on working my way through it this weekend. I'll have to wait until Tuesday to get the socket for the spark plugs but I plan on putting a good dent in it this weekend.