Author Topic: Making some progress (Read 8994 times)

Fezzler · « **Reply #50 on:** April 28, 2019, 04:09:38 PM »

Reminder. Here is progress so far.

Scott S · « **Reply #51 on:** April 28, 2019, 09:56:54 PM »

Looking good!

Fezzler · « **Reply #52 on:** May 28, 2019, 09:28:02 PM »

Well, two hours trying to figure out why in the &%$# world this left crankcase cover will not go on snug, especially at the bottom.

Shoot me. LOL. There was a dowel pin in both the case and engine block. Ugh.

Chain is ever so slightly rubbing the case protector, so off it goes again.

Fun!

Fezzler · « **Reply #53 on:** June 14, 2019, 08:47:14 PM »

Starter in. Carbs on. (New rubber is much easier to install than old rubber!)

Making progress. Adjusted cam chain tensioner. Air box and front brake system next.

Fezzler · « **Reply #54 on:** June 19, 2019, 09:07:20 PM »

Airbox in.

Much easier installation than on my '78 cb550. That bike has the 550 stock airbox but the older Keihin Type 1 627B carbs and matching manifolds (thanks again Cal!). That was a really really tight fit. But it all seems to work well so far, bike runs great and folks say the older carbs are easier to adjust.

On this airbox, I did not get the "pop" sound after finally getting the plenum and air filter box to mate. But everything is tight and snug, so I guess it's time to move on.

Next up is front brake system. I'm following the wonderful SohRon Assembly Guide.

jakec · « **Reply #55 on:** June 20, 2019, 09:38:17 AM »

Can you link the guide? I'll hopefully be needing it this winter..

Fezzler · « **Reply #56 on:** June 20, 2019, 10:21:21 AM »

Here it is; it's just over 40MB. Really an amazing and indispensable guide.

https://drive.google.com/open?id=0B4nqeBb662mZMkxxdmVoWi1IMzg

jakec · « **Reply #57 on:** June 20, 2019, 10:37:18 AM »

That's awesome. I'll be assembling a 400, but this will be helpful.

Little_Phil · « **Reply #58 on:** June 21, 2019, 04:11:22 AM »

Picture of front brake grommet.

Fezzler · « **Reply #59 on:** July 01, 2019, 08:15:10 PM »

Front brake system on; airbox on; pipes on; rear fender, grab rail and lights on.

Pipes aren't the best, hopefully they'll work to get me going and then I can make decisions. Notice PO drilled holes in the back of exhaust (too make them louder?).
I think I'm missing a license plate plate for the rear light assembly. I have to say, for buying this in boxes it is coming together nicely. I have to hunt parts and bolts and washers but they are all there.

Scott S · « **Reply #60 on:** July 02, 2019, 02:54:56 AM »

That's the early style taillight used on the '71 model. The license plate attaches to the little ears on it.

Fezzler · « **Reply #61 on:** July 02, 2019, 06:39:37 AM »

Quote from: Scott S on July 02, 2019, 02:54:56 AM

That's the early style taillight used on the '71 model. The license plate attaches to the little ears on it.

Thanks. I saw in parts book the taillight had several designs back then depending on country. I will say this taillight unit has more "play" with the big rubber pad as compared to my 550. I think I need to replace the rubber bushing in the rear turn signal brackets too eventually. I'm really making progress now that the cold, wet winter is over. Having fun!

Stev-o · « **Reply #62 on:** July 03, 2019, 07:05:18 AM »

Looking good!

Fezzler · « **Reply #63 on:** July 03, 2019, 10:08:37 AM »

Quote from: Stev-o on July 03, 2019, 07:05:18 AM

Looking good!

High praise coming from you! Thanks.

Fezzler · « **Reply #64 on:** July 07, 2019, 10:23:51 AM »

Plodding along and having fun. Big couple of weeks at work so I'll probably not get to next steps until late July. (Points/timing, bleed brakes, check valves/tappet, adjust carbs, check petcock or replace, and then first vroom vroom in I think in 37 years).

On my 550, I found a video or website on checking and maintenance on the advancer. Can't seem to relocate it. Any tips on making sure all is copacetic with advancer?

Also, I bought new shorter pull cable since I have smaller handle bars, turned out to be too short. Installed old one for now.

Fezzler · « **Reply #65 on:** July 07, 2019, 08:51:02 PM »

Okay, new battery charged and installed.

Preliminary wiring/electrical assessment.

- Have Lo/Hi Beam and Off
- Have Instrument lights (Speedometer/Tach)
- Have front and rear flashers and they blink (wink)
- Have "instrument cluster" lights.
- Have rear brake light. (When using rear brake. I have not bleed front yet to test front switch.)
- Have running tail light only when key is in park position. (I remember this on my cb550, it was the ignition switch. Contacts look good on this switch. HMM.)
- No horn. I noticed the light green wire was disconnected in left controls. I resoldered wire to the "button" connector the push button contacts. Still no horn. Horn does work as I tested it with battery directly. HMM.
- No starter. Starter works as I tested it before installing. When I press start button I can hear starter switch relay click but no starter turn.
- Lastly, in the headlamp nest of wires, there is a extra female light green and brown wires with no male counterparts. (Turn signal buzzer I think?)
- Also, the ignition wiring was getting warm if not slightly hot. Short?

To Dos:

- Test starter relay switch
- Study wiring and make sure all connections are clean and in proper place.
- Horn wiring. Does the button complete the ground and that make the horn work?

So basically I want to test before needlessly swapping parts. But I will if I need to.

Fezzler · « **Reply #66 on:** July 28, 2019, 10:09:48 PM »

Getting close to making sure everything is button down, tight, set up carbs, and try to start this '71 Honda cb500 four K0 I bought in boxes a long time ago (year and a half?). Update to below.

- front brakes bleed and working
- I have running tail light. '71 has off switch for headlamp that also turns off running tail (live and learn).
- Starter is now turning with press of a button. Ignition wires fixed. Starter relay good.

One issue. Even with new button, horn does not sound. Horn does work, I tested. I'm wondering if the two wires not being used (see pic in previous post) in the headlamp are not for the turn buzzer but rather for the horn. Or does the buzzer need to be installed to complete circuit the horn button is on in the K0 model. Driving me a little mad. Oh well, I know I'll get it soon.

In the humor category, parts bike came with stash of some new items. One of those was a set of new Honda spark plugs. I put in 4, 3, 1 and then 2 would go in for the life of me. I assumed I was just not lining it up. I tried for like 25 minutes or more. Finally I compared new plug to the one that came out. New one was smaller. What? Check box, yup, one of the for was not the same plug. LOL. UGH!

jaytee-nz · « **Reply #67 on:** July 28, 2019, 10:22:33 PM »

Fezz - I had the same issue with the horn on my bike and if I recall correctly some versions are designed to be grounded on the frame through the light green wire. I attached mine to one of the bolts for the coil mounting (remember to scrape off the paint so there is bare metal for the ground). Hope that works for you.
Bike is looking great by the way.

Fezzler · « **Reply #68 on:** July 29, 2019, 09:45:46 AM »

You just gave me a great clue!

I had my frame and upper triple tree powder coated. And I painted my instrument panel and gauge bracket. I wonder if I have insulated my handlebars from the bike and they are no longer able to complete the ground when the horn button is pushed? (I did grind all other connection points to bare metal.)

I need to check that and fix it if it is the case. Or connect a wire from the handlebars to a ground. Thanks! I'll report back!

(I wonder if any other device is relying on the handlebars to complete ground?)

Quote from: jaytee-nz on July 28, 2019, 10:22:33 PM

Fezz - I had the same issue with the horn on my bike and if I recall correctly some versions are designed to be grounded on the frame through the light green wire. I attached mine to one of the bolts for the coil mounting (remember to scrape off the paint so there is bare metal for the ground). Hope that works for you.
Bike is looking great by the way.

jaytee-nz · « **Reply #69 on:** July 29, 2019, 12:57:19 PM »

I thought I had the same issue with the handlebars etc as you say, but in the end the only way I got the horn to work was through directly grounding the light green wire. Worth a shot though.

Scott S · « **Reply #70 on:** July 29, 2019, 03:14:16 PM »

I had to do that with a turn signal once. Only one of the four, stock signals and everything. Ran a small ground wire to the lower triple tree bolt.

Fezzler · « **Reply #71 on:** July 29, 2019, 09:05:05 PM »

Well I tested the handlebars for continuity tonight and it was there. HMM. Studied the rats nest in the headlamp. Played around.
Last ditch effort, I said, "why don't I plug the light green bullet into the light green female that is for (I thought) the turn signal buzzer and see what happens.

BEEP, BEEP.

Solved.

I'm done with assembly. I want to check all the bolts. Make sure all wiring is snug and placed where it needs to be. I need to pull the rear wheel and see if I can be patient enough to get it more true that it is. Fine tune the cables. Set up the carbs. Then Vroom vroom time.

Should I put a little oil in the spark plug holes and crank by hand to get some lubrication before first start in what I believe is about 30 years?

I'm also think of creative ways to fill and cover the holes poked into the end of the exhaust pipes. I'm not looking for it to be loud.

Lastly, the alternator emblem cover is missing the three posts that allow it to snug into the clips. Recommendations? If double-sided tape, I imagine the strongest I can find.

If all goes well I'll have this titled and on the road by Sept.

RAFster122s · « **Reply #72 on:** July 29, 2019, 11:14:20 PM »

Congrats on the working horn and light at the tunnel's end calling to you... So, head for the light and double check your fasteners to ensure it will be a safe first ride. A bit of oil in the top end would not be out of the question... Ideally getting oil pressure before starting never hurts...
David

Scott S · « **Reply #73 on:** July 30, 2019, 03:38:25 AM »

Get some of the thinnest 3M tape that Autozone sells. It'll old the side cover just fine.

Oil in plug holes is a good idea. Ignore the smoke at first. You can also kick it over a few times with the key off.

I'd see how the exhaust sounds first before worrying about the holes.

Fezzler · « **Reply #74 on:** July 30, 2019, 08:33:39 PM »

Okay, some items as I start buttoning up before Vroom Vroom.

I started with the clutch. My 550 clutch is perfect but, frankly, I feel I dialed it in by luck.

So beginning with the manual. I loosened the clutch adjuster lock bolt. As I tried to turn the adjuster clockwise, it would not budge. Tighter than clam at low tide. Stuck is fair description too. I gently tapped it counter clockwise ever-so slightly and it was still very stiff still but it moved a tad. I don't want to strip it so I tightened the lock bolt and moved on.

I did "Decrease free play" at the cable. It's okay, but at the grip it's a tight feel not a smooth resistance like on my 550. So hard pulling in, but the resistance going back is more spongy than firm/smooth. So kinda a total lost here but another observation.

The bike goes into neutral and first easily but not 2, 3, 4 at all. Now, I had the same thing on my 550 until I got it off the center stand and heated the engine (and oil) I'll presume. The clutch is probably sticky. Right?

Also, the neutral light stays on when in first. Also, I recall when putting on the sprocket cover case it was tight fit. I had to push it into position really firmly. I assumed it was normal as the case helps push the lifter rod against the clutch and pushes in the springs. (?). After clutch, I'll move to rear brake an then carb. Then address the ear wheel not being as true as I like.

(PS - 500's horn has much better tone than the 550 IMHO)

News:

Author Topic: Making some progress (Read 8994 times)