Topic: 72 CB500 Restomod - *Update* Sold!

[Scramps]

There were some really bad runs in the paint, so I sanded it back down to try again. I think I’m gonna try to find something a little closer to the color of the 750 I posted a while back, the yellow I had was a little too bright. Also there’s some dents and pitting that need to be addressed

[Scramps]

Found a couple of wires that had pulled out of the connector for the coils. Thought my plugs were fouled, but they weren’t firing because they weren’t getting a signal.

I’m going by O’Reilly for a couple sets of plugs for testing tomorrow after work. We have a commercial account with them and they pass those discounts along to us, which is pretty nice.

[Scramps]

One of my carburetor bowls developed a leak during the disassembly, cleaning, and reassembly. No biggie, just a squished o-ring.

I put my kickstarter on, had been ignoring it.

I'm having some difficulties with the clutch cable. I can't seem to be able to make it actually depress the clutch, and I haven't had much luck finding any information about setting up the actuator to make it do its job. I either get it so tight that it can barely be pulled, or so loose that it has no resistance.

The push rod is intact, and the ball in the actuator is still there.

[Crazy Horse]

Really enjoying your build thread Scramps. Bikes coming along nicely 

[Scramps]

Thanks, crazy horse! I’m enjoying building the thing.

But about the clutch lifter, I’ve installed it as is indicated in the original shop manual, but it’s not working. I’m going to drain the crankcase and pull the clutch cover to make sure I didn’t screw something up or miss a part on it.

[RAFster122s]

Dave500 is needed to chime in if Calj doesn't. PM Dave...

[RAFster122s]

CLR can clean up brass, just don't soak it a long time, 30 minutes loosens up the crud on brass usually, fwiw.

[Scramps]

I haven’t even had a chance to get into the garage all week, and the coming week doesn’t seem too promising. Thanks for the tip RAF

[Scramps]

I don’t think that it was the culprit, but I am ruling it out; a large portion of the dividing wall that divides the inside my sprocket cover was broken and missing. I had thought that it wouldn’t be a huge issue, but now I want to fix it. I have ordered an intact replacement, along with a factory air box, which will change some things for my carburetor setup.

I’ve been rethinking several of the design choices, namely the paint scheme. I took a little time today to try and restore some semblance of smoothness to my side covers after I mangled them several weeks ago. They don’t look amazing, but they don’t look like a horror show anymore.

I sanded and cleaned and primed and painted them white for now. This will be a base layer for something else.



Feels good to be working on the bike again! I can hardly stand to be away from it for long.

[Scramps]

Okay, so, pulled all my components out that are supposed to move the clutch. From what I can tell, I’ve got all the things, but I am absolutely not an expert. Does anyone see anything amiss? Any help would be very much appreciated

[Scramps]

My apologies, I know that the clutch lever is a perennial issue on the 500s and has been discussed endlessly over the years. I should have done some digging before I pestered you fine folks with the same questions that have been asked a thousand times.

[Scramps]

Would I be better off just swapping everything over onto the 550 bottom end that I’ve got?

[Scramps]

On that note; does the rod in the picture look to be the correct length? Size does matter in a purely functional sense here

[Scramps]

So I’ve been on a kind of forced hiatus lately with all the hours I’m having to work, and what little time I have had to work on the bike has been rushed and in a state of exhaustion.

I know I can figure out this clutch thing and get everything back on track, but today I had another annoying setback. I put the clutch cover back on the engine and put some oil back in the crankcase, and of course that cover is now leaking like a sieve.

I’m strongly considering cutting my losses at this point, but I know that would be a foolish mistake. Instead I’m going to try to take an actual hiatus, if my brain will allow it, because I’m going to end up breaking something important if I keep working on the bike in brief, rushed sessions while sleep-deprived.

Godspeed to you all in your endeavors, and I’ll be back sooner or later

[Scramps]

Another magnificent YouTube channel to watch if you’re into building motorcycles is BMCO (Born Motor Co.)

https://www.youtube.com/channel/UCsJU17u9dqtsG8Dy7VF067A

It’s these sped up time lapse close up shot videos of bike builds (mostly trackers) by this Spanish guy. They’re mesmerizing to watch

[DurangoCB]

That’s maybe my favorite YT channel. The sped-up videos are good for however it is that my brain functions. Love all the little fab parts and brackets he makes.

[Scramps]

That’s maybe my favorite YT channel. The sped-up videos are good for however it is that my brain functions. Love all the little fab parts and brackets he makes.

High five!

I’m currently watching the whole playlist on a loop. I’m excited to see how his little Yamaha is going to turn out. He’s getting a lot more in depth on this one than usual


Sent from my iPhone using Tapatalk

[Scramps]

Okay!

Possible solution to the clutch disengagement issue. Two parts.

One: old wet clutch + watery crankcase * a couple decades or so = stuck friction plates. Removed them tonight to discover that they are indeed rusty and sticky, so I’m gonna clean ‘em tomorrow and see what I end up with.

Two: I don’t think that 100% of the hardware for the springs on the clutch basket is present. I will investigate this further during reassembly.

I also confirmed the movement of the actuator rod is as it should be, and that it should be able to do the job provided that everything else shakes out for the better tomorrow.

[Scramps]

Backing up and redoing some stuff. Carb adjustments to suit the stock airbox, some electrical component relocating, and some fabrication. I really wanted to get this bike on the road as quickly as possible, but that's not going to happen.

Back on the clutch thing, None of the stuff I've done so far has been very helpful. My friction plates are 3.4-3.5mm, and the only spec I could find indicates that 3mm is the wear limit, is that legit?

I'm probably going to need new springs?

Anyway, have fun

[Scramps]

I purchased an 8mm nickel-plated steel rod, cut it to the only length dimension I could find (257mm), and voila:

It's just a touch too long, I left some excess for rounding off the end.

I'm glad to finally have this damned problem behind me, or at least nearly.

[Scramps]

So for future reference, the push rod does need to be 257mm long, 8mm in diameter, rounded on one end, with a 10mm long section of the rounded end lathed down to 7.4mm diameter, to allow it to seat in the lifter. The other end remains flat, with a small indentation for the steel ball in the lifter arm.

There has been some discussion about hardening the tips to prevent premature wear and tear, but I’m not 100% sure that the application is strenuous enough to warrant that. Thoughts?

[Darren Jakal]

Yea the moment it finally comes together.  You can hear it in your voice.

I enjoyed the video!

cheers, dj

[Scramps]

Thanks DJ, I was very excited.

[Gurp]

Scamps. I was going nuts with my clutch. Gordered that bracket from you. Have a new cable and read throigh here since im building a 73 cb500 and measured my clutch rod and its 254mm.  I havent got the clutch side apart yet to see if the plates are stuck or not though lol. Is there a bracket on the 500 or does it just go in the hole on that sides cover?
This is my first 500-4. Had a few 550s but dont know what all is different.

[Scramps]

Clutch cable feeds down through the top of the left side cover.
The 500s also have a shorter clutch cable than the 550s.
It was a carryover design from some older, smaller machines that they ultimately changed later on.