Author Topic: Bench sync 500  (Read 1129 times)

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Offline Kevnz

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Bench sync 500
« on: December 29, 2021, 09:26:28 PM »
Season's greetings Team,
I built up the courage to start my project 500 today, apparently hasn't run in many years. I checked and cleaned the carbs which were mint inside, but, as the adjusters still had their yellow locking paint on them, I decided not to miuck around with the sync. Bike started first go, but went straight to about 4K revs.  Can anyone guide me on how to bench sync these, please?  What size drill ( gauge) and do I adjust on the cutout side or the manifold side? At the cutout, the measurement is about 5- 5.5mm, which seems a bit large.
Thanks,
Kevin
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Offline TwoTired

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Re: Bench sync 500
« Reply #1 on: December 29, 2021, 10:16:15 PM »
There is no master factory carb, so you have to assign one and make sure that with the idle knob turned out that carb will fully close.  Then lock that carb down, and never adjust that one again. THen adjust the others to what opening your master carb is. Tweaking all the adjusters usually results in the slides being unable to fully reach the bottom of travel to base of the bore.  The big idle knob should have sole authority for that task.

I don’t use drill bits. I use a light shining in one side closing off when the slide reaches bottom.  When they are all the same, the idle knob opens them all to achieve proper  idle.

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Lloyd... (SOHC4 #11 Original Mail List)
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Offline Kevnz

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Re: Bench sync 500
« Reply #2 on: December 30, 2021, 12:01:36 AM »
Thanks for the response Two Tired. I think I have found the issue. There was some grot sitting in the groove preventing one slide from fully seating. You couldn't see it without removing the slide. What a PITA that is, I'd hate to be changing the needle positions too often! I'll set that one the same as the others as they don't appear to have ever been adjusted previously, refit the carbs and see what happens. Even though it revved the snot out when it started, inital impression is the engine is sound, which is good news.
Thanks again
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Offline Deltarider

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Re: Bench sync 500
« Reply #3 on: December 30, 2021, 12:34:03 AM »
First of all, I'd respect that yellow locking paint. Honda did much effort to have carbs which hardly need syncing. Checking - preferably without disturbing things - is OK though.
The high idle can well have another cause, like the central idle adjuster needing readjustment*, airscrews turned out too far, a non OEM airfilter element and/or airleaks. As far as bench syncing, I had success using a small allen key gauging the small opening manifold side. You need to be concentrated though and do it by feel, which means: take your time. Some use steel balls which should drop simultaneously. Making a pic of where the adjusters screws are now, wouldn't hurt. It is well possible Keihin handed the racks over to Honda with the adjuster screws all having the same postion, number of turns wise. Personally I find the light method rather inaccurate.
* Realise that the CB500 needs a raised idle when cold and the first mile or so. Some keep the throttle somewhat open, as the Owner's Manual suggests, others (like me) use that idle knob for that.
Warning: do not try to achieve a highest idle possible by turning the airscrews out. Although this may work on other motors, the result on yours will be a serious loss of driveability and possibly a hanging idle.
A standard check before turning to the carbs, is to verify the throttle cables do not hamper operation and the ignition advancer moves smoothly. It goes without saying that ignition timing is correct and plugs and plugcaps are sound.
« Last Edit: December 30, 2021, 05:46:59 AM by Deltarider »
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Offline Kevnz

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Re: Bench sync 500
« Reply #4 on: December 30, 2021, 01:23:37 AM »
Thanks Deltarider. I checked the settings using my gas torch tip cleaners as gauges, and 3 were almost identical, so I left them as were. Obviously I had to disturb the other one to repair, but have now set that one the same, probably all the same within a thou or two. Carbs back on bike, too late to try tonight. Will update tomorrow.
Thanks again
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Offline bryanj

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Re: Bench sync 500
« Reply #5 on: December 30, 2021, 03:06:15 AM »
Over on the UK forum in tricks and tips is a write up i did years ago
Semi Geriatric ex-Honda mechanic and MOT tester (UK version of annual inspection). Garage full of "projects" mostly 500/4 from pre 73 (no road tax in UK).

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Offline Kevnz

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Re: Bench sync 500
« Reply #6 on: December 30, 2021, 01:20:18 PM »
Good news and bad news. Bike started straight up, and I was able to adjust the idle using adjuster and engine seems good. Bad news, immediately dumped 1\2 a cup of oil on the floor, left side. Seems someone modified the head ( who knows why ?)
Going to try a repair with JB Weld first, otherwise will need some welding or a new head.
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Offline bryanj

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Re: Bench sync 500
« Reply #7 on: December 30, 2021, 01:39:03 PM »
Someone was a raging pillock
Semi Geriatric ex-Honda mechanic and MOT tester (UK version of annual inspection). Garage full of "projects" mostly 500/4 from pre 73 (no road tax in UK).

Remember "Its always in the last place you look" COURSE IT IS YOU STOP LOOKIN THEN!

Offline scunny

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Re: Bench sync 500
« Reply #8 on: December 30, 2021, 01:44:20 PM »
what were they trying to do ?
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Offline bryanj

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Re: Bench sync 500
« Reply #9 on: December 30, 2021, 02:35:35 PM »
That would be my second tyrade, at least the oil there is not at fullpump pressure
Semi Geriatric ex-Honda mechanic and MOT tester (UK version of annual inspection). Garage full of "projects" mostly 500/4 from pre 73 (no road tax in UK).

Remember "Its always in the last place you look" COURSE IT IS YOU STOP LOOKIN THEN!

Offline dave500

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Re: Bench sync 500
« Reply #10 on: December 30, 2021, 08:29:03 PM »
have you got the cap cover for that side?

Offline Kevnz

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Re: Bench sync 500
« Reply #11 on: December 30, 2021, 11:13:35 PM »
Hi Dave,
Yes, have the cover. I actually went to the trouble of buying new, correct top and bottom washers for the bracket, trimmed the bracket where they get distorted by hamfistedness so that the washers seated nicely,  and put that together without even noticing the damage to the head. Not noted for being observant! Here's the repair, hope it holds out. My previous 500 had the posts that the ignition plate seats on damaged (crash?) and I've had success repairing that with JB Weld, so here's hoping. As Bryan says, not a high oil pressure area; at least I know I'm getting plenty of lube upstairs.
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Offline jaytee-nz

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Re: Bench sync 500
« Reply #12 on: December 31, 2021, 01:13:47 PM »
Nice work Kev - no reason why the JB Weld won't work.
I remembered that I didn't answer your question from another post a while ago about my CB500. I ended up selling it a year ago now. I was offered too good a price to turn down, but at least it's still in New Plymouth and I know the new owner.
Still got my CB750 that I've had for 8 years.
Cheers - JT.

Offline Kevnz

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Re: Bench sync 500
« Reply #13 on: December 31, 2021, 03:05:46 PM »
Hi Jay tee,
Happy new year. I've just got the valve cover back on and readjusted the tappets. Started up ok, but I haven't run it long yet.
Hoping all will be well. Did you see the gold 500 on TM a couple of weeks ago? That was the other one of the pair I bought last year, now have some funds to finish the green one. Hope you have a good day,
Cheers,
Kevin
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