Topic: 1978 CB550K Barn Find Build

[skinsfn36]

Hi all

After weeks of lurking and learning, I decided to make an account and bring y'all along the journey of my barn find build.

One day on Craigslist, I came across an estate sale that had a picture of a barn on it. In the back of the barn I saw a bike and decided I would go check it out.

There sat a 1978 CB550, last inspected in 1982 and totally seized up. Pitting and some surface rust, but all in all it was in decent shape, sans the engine. I offered the guy $150 and he gladly took it and I drove away with it in my pickup.

I plan on doing a full, frame-off Resto-Mod, Tracker style.

Day 0: Got the beast home and power washed the entire thing, top to bottom. Took the tank and seat off and rolled it into the garage.



Day 1: Started breaking everything doing and disassembling the motor. This was especially difficult as it wouldn't turn. It was a challenge but I managed to cut the head off one of the cam gear bolts and had access to the other and was able to get the cam chain off for disassembly. Got the Valve Cover and Cylinders off. I can't tell what happened, but my guess is water got into cylinder 3 and rusted the whole thing up.




Day 2: Got almost everything out / off the frame and continued to break down the motor.

I am at my first block in the road and it seems like I can't get the two shells for the crankcase to come apart. I've got everything according to the Cylmer manual off, sans the stator rotor. Does the absolutely need to come off?

I just want to get in there and look around. The rods are a little corroded and I want to make sure that nothing else down there is rough. In the barn the bike had no oil pan drain plug or oil filter, so moisture was able to get into the crankcase. The pan was covered in sludge on the inside.

[skinsfn36]

I took the cylinders over to a machine shop today and they told me that the damage done by the seized cylinder was too heavy to hone.

Time for a big bore! Luckily I had already been eyeballing that eBay 61.5mm kit so I went ahead and ordered it. Once it comes in I'll be dropping the cylinders and head off at the machine shop for boring and clean up.

[CycleRanger]

I am at my first block in the road and it seems like I can't get the two shells for the crankcase to come apart. I've got everything according to the Cylmer manual off, sans the stator rotor. Does the absolutely need to come off?

Howdy! That looks like an ambitious project for sure.
Do you have the Honda Shop Manual? You can get it and the parts list here.
http://www.honda4fun.com/materiale-documentazione-tecnica/shop-manual
http://www.honda4fun.com/materiale-documentazione-tecnica/parts-list/parts-list-cb550

[calj737]

If the pictures you posted of the motor in disassembly is it’s current state, you have quite a few more bolts and screws to remove before splitting the cases.

[skinsfn36]

No that’s not it’s current state.

I’ve removed the clutch cover, clutch, shifting mechanism, oil pan, starter, and all of the bolts I can find. 

I didn’t think I needed to remove the stator, but maybe I do.

Thoughts?

[SOHC4 Cafe Racer Fan]

Thoughts?

Get to be Cal's (call737) new best friend.  He's in you town and, if you are nice and appreciative, he's a great source of knowledge and help.

[skinsfn36]

I would love to meet some locals that are doing or have done some work like this!

This is my first time doing anything this in depth. I’ve been working on cars for about a decade, but not motorcycles or fully engine tear downs

[Camrector]

Cal meet your new best friend! I can’t wait to hear about the abuse he puts you and your wallet through!
 

[calj737]

LOL! Dang, I never noticed guys... a bit preoccupied with the boy and his bike these days.

Alright, Skinsfn, I’ll pop over and help on one condition: don’t even talk that nuisance American Thug Ball crap to me. Football is played in Europe with an athletes feet and they play it on a pitch!

We good?

There’s another new member, Jooky who also has a 550 and is just beginning on his refresh. Have to get everyone together. I’ve got a wicked good machine shop for you over off Hilliard and Staples Mill, Ballos Machine to deal with the head and bores unless you can step up and afford Mike Rieck’s Magic Motor services? Then you’ll have a screamer of an engine!

I’ll send you a PM with my contact details. If you ever turn up wearing leopard skin gear and Hoe Depot gloves, you’re done. Sabé?

[Lostboy Steve]

I wish I lived near you guys. #$%*, I’m tired of being the only lunatic on an old 550.


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[skinsfn36]

LOL! Dang, I never noticed guys... a bit preoccupied with the boy and his bike these days.

Alright, Skinsfn, I’ll pop over and help on one condition: don’t even talk that nuisance American Thug Ball crap to me. Football is played in Europe with an athletes feet and they play it on a pitch!

We good?

There’s another new member, Jooky who also has a 550 and is just beginning on his refresh. Have to get everyone together. I’ve got a wicked good machine shop for you over off Hilliard and Staples Mill, Ballos Machine to deal with the head and bores unless you can step up and afford Mike Rieck’s Magic Motor services? Then you’ll have a screamer of an engine!

I’ll send you a PM with my contact details. If you ever turn up wearing leopard skin gear and Hoe Depot gloves, you’re done. Sabé?

Ballos is fantastic! They did work on my old H22 motor back in the day. Glad to hear they're still around and killin' it. Is Stewart still there? Davis Automotive and Machine came recommended to me as well, any word on those guys?

I'm certainly down with a get together! I'm shooting for spring to get this thing done, but I'm not going to rush anything.

I'm technically out in Powhatan, but no one knows where that is, so I put Richmond.

I dropped by Cognito Moto's shop on Friday, super nice guys in there and a clean facility. I'm sure I'll be using a few bits and pieces from them.

[calj737]

Yup, Stewart and his brother are now running the place. Dad’s retired. Their mom passed last year. Nobody better in Richmond for machining these motors than Stewart.

Devin and his crew are also completely awesome guys. My second boy was working there last year part time, and I’ve known Devin for about 5 years now, since his humble roots. It’s a small town, but filled with plenty of great, small craftsmen. I’m down in south Chesterfield, very near Petersburg so Powhatan is on my regular ride towards Oilville, Goochland, Scottsville and beyond. A quick spin out Beach to Hull Street and blast right on by. Don’t blink... 

[skinsfn36]

Yup, Stewart and his brother are now running the place. Dad’s retired. Their mom passed last year. Nobody better in Richmond for machining these motors than Stewart.

Devin and his crew are also completely awesome guys. My second boy was working there last year part time, and I’ve known Devin for about 5 years now, since his humble roots. It’s a small town, but filled with plenty of great, small craftsmen. I’m down in south Chesterfield, very near Petersburg so Powhatan is on my regular ride towards Oilville, Goochland, Scottsville and beyond. A quick spin out Beach to Hull Street and blast right on by. Don’t blink... 

Do you know off the top of your head what a bore will be from Ballos?

[calj737]

$40/hole with a rigid hone. You’ll also want the deck milled flat. Same for the head. Stewart will record the total mill-cut and trim the locating dowels the equal amount.

If you want an overbore and performance, the Wiseco 59mm pistons are a great choice. Leaves ample cylinder sleeve thickness. Punching out to 61+mm isn’t going to make your bike a fire breathing dragon... Oversized intakes, quality slugs, good cam, and a tight squish is all you need.

Check out Flatlanders 550 build thread. He used a similar recipe and got great results.

[skinsfn36]

I took the cylinders by Davis and they were concerned that the damage done by the seized piston was going to require an overbore. Theres a layer of nastiness on the cylinder walls above where the cylinder was seized and partially exposed to the elements.

I picked up that 61.5mm piston kit and plan to run with that.

Not looking for a fire breathing dragon, I've done the super fast bike thing, it's not fun, just scary.

[calj737]

The 61.5 kit will thin the sleeves pretty far, leaving little wall thickness at the bottom, essentially removing the taper. Use extra care when installing the pistons and rings to avoid catching and chipping that edge.

What cam change are you planning? The Megacycle 126-00 is a very good street motor choice. Bundle that with new Kibblewhite guides and 28mm intakes, and your motor should be decently healthy. An adjustable cam sprocket is a must have with a non-stock cam to dial it in. And a tight squish of about 38 thousandths using an MLS gasket should make for nice compression.

[skinsfn36]

The 61.5 kit will thin the sleeves pretty far, leaving little wall thickness at the bottom, essentially removing the taper. Use extra care when installing the pistons and rings to avoid catching and chipping that edge.

What cam change are you planning? The Megacycle 126-00 is a very good street motor choice. Bundle that with new Kibblewhite guides and 28mm intakes, and your motor should be decently healthy. An adjustable cam sprocket is a must have with a non-stock cam to dial it in. And a tight squish of about 38 thousandths using an MLS gasket should make for nice compression.

I wasn't actually planning to do a cam change, maybe a 650 cam or the Dynoman WebCam. I hadn't heard of Megacycle, I'll do a little research.

I'm not trying to do a ton of engine work that I don't absolutely have to. The boring is due to the inability to hone because of damage.

[calj737]

Mega cams are a little "better" than Web for the 550. They tend to be closer to their timing card and easier to time. The 650 camps a decent swap.

[skinsfn36]

Mega cams are a little "better" than Web for the 550. They tend to be closer to their timing card and easier to time. The 650 camps a decent swap.

If I can find a 650 for a good deal, I'll do it.

Right now, just focused on getting this case apart!

[calj737]

Pull the rotor

[skinsfn36]

Pull the rotor

Going to try this weekend! Made an agreement with the wife if I was going to buy another project, it would only get weekend attention

[SOHC4 Cafe Racer Fan]

If you ever turn up wearing leopard skin gear and Hoe Depot gloves, you’re done. Sabé?

Hmm. Maybe that's why that "other guy" from Upstate NY is no longer on the Christmas card list!  He started dressing like the Wilde Man. . .

[calj737]

Bingo.

[skinsfn36]

Pull the rotor

Is the easiest way to do it without the special tool just using a long 16mm x 1.5mm bolt?

[calj737]

That can work if you don’t have the tool.