Topic: Looking for Tip/Tricks/Advice - 550 Engine Rebuild

[AEngelsrud]

Hi all!

I've read through a bunch of the old engine rebuild threads and I'm not finding what I'm looking for - so I thought I'd just put it out there for community consumption. Here goes....

So, Saturday (7/15/17) I'm starting a complete 1974 CB550 engine teardown - right down to the oilpan. I'm going to get the engine coated (either powder or thermal dispersant) and then rebuild from the ground up. I've purchased the top end video from Bochnak (https://www.howtomotorcyclerepair.com/cb550topend/) and watched it several times. I also have been in contact with him a couple times with some questions (THANKS!). Additionally, I have the full CB500/CB550 service manual printed and in a binder ready to go. Finally, I have the engine pulled out of the frame and relocated to a clean/well lit workshop. I should have all the tools I need - already bought a valve spring compressor, an impact driver, and loads of shop towels.

So, given all this - here is where I'm looking for help:

What is the best way to organize this teardown so I can actually rebuild it some day? Should I take pictures of everything? Do I need bins to store stuff? How much detail should I put in organizing the teardown? Do I separate and label all screws, nuts, bolts, and washers by part/component? I figure there are loads of you who have done this and have methods that WORK - why reinvent the wheel? I really want to do this in a thoughtful, smart manner - I don't want to end up with a garage sale box of "motorcycle parts".

Any help or guidance is appreciated.

Thanks!

Aaron

[CBGhia]

I would say that you want a decent sized table to lay things out on.  I would suggest using lots of cardboard.  Draw a picture of the thing you are working on and put the bolts in the proper places.  That will allow you to put it all back in the same place.  Also pictures.  Take lots.  From different angles.

[Stev-o]

+1....photos, from different angles.  Bag and tag all small parts and hardware.

BTW - not sure what "thermal dispersant" is, but have you considered vapor blasting?  I recently finished a rebuild on my Kawasaki H2 and had the entire motor vaper'd by Nils, it looks fantastic!

https://www.restocycle.com/vapor-blasting

Good luck!

[strynboen]

i have a lot of plastic boxes..and put schrevs and small parts.
.for eks head/kaburetors..and so in separat boxes..it make it easyer to hold system..and make the parts holds in a Group vith the bolts( vho are used it that areia.).so i have all head bolts in one box..and oil pan bolts in a other..and yes a big klean tabel..to put the parts on..as they are taken aut ..and a engine stand..is nice too..

[magnum56]

I used a few bins, but honestly I used many more zip lock style bags of varying sizes.
Label the bags as necessary, or include any notes or descriptions in the bag with the stuff.   

And yes, lots of pictures ... much easier now with smart phones. 

The time and patience you spend on your tear down and inspection process ... will likely pay you great benefits when you are ready to reassemble. 

[AEngelsrud]

Lot's of GREAT info so far - keep it coming! Thanks!

So far:

• Take lots of pictures of process and parts
• Work slowly and in stages
• Inspect parts as they are coming off the engine
• Use baggies for loose parts (need to get some heavy duty ziplock bags)
• Lot's of table space for laying out parts

Aaron

[Stev-o]

• Use baggies for loose parts and hardware and label

Fixed. 

Also - put  screws and bolts back in place if possible.  For instance, replace bolt in shifter lever and it has been removed.

[bochnak]

Here are some tips:

1. Buy plastic sandwich bags & sharpie. Bag and label everything.
2. Buy a cheap plastic folding table to store disassembled parts (ref link):
https://www.amazon.com/Cosco-Deluxe-Molded-Folding-Speckle/dp/B001D25TJQ/ref=sr_1_3?ie=UTF8&qid=1499978570&sr=8-3&keywords=folding+table

3. Start laying out parts at one end and work towards the other as you disassemble.
4. Take pics.
5. Take notes as you go along and highlight parts in parts diagram that need replacement. This avoids missing an a parts that needs to be ordered.

Thanks for buying the video

Matt

[strynboen]

as cal says...
 keep the orentation of pistone/valvets plain bearings..puts labels or hammer dots..so all parts gets reight back..cylender numbers 1-4..also goes for valvets rockers and plain bearings..

[DaveBarbier]

Also agree 100% with drawing the part (let's say the valve cover) on a piece of cardboard and sticking the bolts/screws into the cardboard in the proper place. Makes things much easier.

I'd avoid powder coating the head or cylinders. Powder coating will act as an insulator. Since these bikes are air cooled, they need all the help they can get.


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[DaveBarbier]

I guess I'm used to my powder coating where it's way too thick, haha. I was reading about people not liking powder coat because many believe it holds heat in. I was also talking to Rick Stetson about this too on his race motors. I should have said I have no evidence for this though.


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