Topic: 1976 CB550K - Another new project

[Bristledisk]

Hi All,
I just acquired a running but ratty 1976 Honda CB550K. My plan is to return it to near stock. This will be my second restoration after completing my Honda CB400F. I learnt a lot from that project and will apply some of my newly acquired skills and tools to the new project. Lots of parts are missing including the seat, airbox, tank badges etc. The rear fender was all taped up ready to be chopped but luckily the PO never got around to it. This will be a long term project. My plan is as follows:
1. Evaluate what's missing and start to order the harder to get parts - 4 into 4 exhaust, airbox assembly etc.
2. I know it was running just before I picked it up but I once I get the airbox assembly I plan to give it a 3000 mile service and get it running.
3. Strip down the bike and get the frame powder coated.
4. Top end rebuild depending on the results of the compression and leak down test.

[Stev-o]

Congrats, looks like a good candidate for a restore. Good to hear you are ditching that seat!

[Elvarko]

Great bike, will be fun to bring her back to normal. I spotted a missing part if it helps you?  The chain. 

[calj737]

Shame about the smashed in thank 

[SOHC4 Cafe Racer Fan]

Ooh. That seat is almost as attractive as a king and queen seat.

[Bristledisk]

Update: Because the bike was partially disassembled when I got it and had been cafe'd, I decided to fully assemble the bike to see what I have and didn't have.  The SohRon thread - CB550 Assembly Manual is proving really useful for this. It's a step by step pictorial guide and allows me to quickly see what's missing plus provides some great tricks and tips.

So far I replaced the Ace bars with stock bars purchased from SOHC local member fireblane and re-added the missing air box purchased from the Internet. I also bought a new plastic rear B fender as the PO had cut the old one in half. 

New 4 into 4 pipes are on their way from DSS along with the replacement seat.

It's proving pricey (don't get me started on shipping costs to Canada) but I'm having fun.

[Bristledisk]

My plan for this bike was to acquire all the parts, get her running and then start the restoration proper.

There was a lot more parts missing than first thought. That box of parts that came with the bike promised much but delivered little containing parts from bikes other than the 550K.

Anyway I now have the elusive seat bracket, fork ears etc. The replacement electrical loom was from an early 550K requiring a SSU which the bike doesn't have. For now, I've bypassed the SSU until I either get either an SSU or build my own equivalent. I've seen a few posts on her on how to do that. But for now the start motor whirrs, turn signals wink, horns hoot, light illuminate.

I hooked the bike up to the auxiliary gas tank and after a few tries, it started up. Strangely enough, it wouldn't start until after I did a compression test on one of the cylinders.

I only ran it briefly. It's running rough but idles okay.

Next step is to clean the carbs and then remove the engine and tackle the purple frame.

[firebane]

That purple frame looks awesome! Lol. Glad to see the bars found a good use.

If you are looking for a home for those ace bars let me know.

[palepainter]

I can almost see that tail section in the Smithsonian.   

[riverfever]

What is the story on the seat? Who made it? I wanna call it a sender. Seat AND fender.

[Bristledisk]

Firebane: you are welcome to the Ace bars. No charge. Just PM me.

The ugly seat/sender is in the trash. Beauty is in the eye of the beholder I guess.

For some reason I like the giant turn signals and stock rear lights of the North American 70s Hondas. Others hate them.

[Bristledisk]

Progress 3 months in:
1. I finally started using the cheapy Princess Auto bike lift. Its rather narrow so difficult to get the bike on and then onto the centre stand. I eventually got the missus to help.
2. I've just about accumulate all the missing parts as the bike was only partially compete when I got it although I always seem to need just one more thing.
3. I'm still getting the bike together and running before the strip down to powder coat he frame and do what ever engine work is required. I got hold of an SSU from a forum member (Thanks) and the wiring is complete. Every thing works.
5. I stupidly cracked the oil pan changing the oil by another forum member (Thanks) was able to supply me a replacement.
6. The bike starts and idles okay. Not brilliant but I haven't tried to tune/service it yet. That's the next step.
7. I would get on quicker if I didn't keep riding my other bikes 

[Bristledisk]

My goal with this restoration is to do as much as I can myself and pick up some new skills.

So today I ventured into new territory attempting to remove the dents from my badly battered cb550 tank. Bear in mind I'm learning as I go along.

1. Removed the old paint from around the dent using my air grinder and bristle disk.
2. Knocked up a little jig to hold the tank in place
3. Used my cheapo second hand stud welder to weld on a few studs.
4. Used the slide hammer to gradually pull out the dings.

This is definitely a work in progress and learning exercise but I'm making progress. Given enough patience, the dents should come out ready for skim of filler.