Topic: 1974 CB550 Build Log

[kenjataimu]

Started multiple cafe racer projects, but they always ended with me frustrated and selling a pile of parts. But this time, I promised myself it would be different--I wouldn't get way ahead of myself and just chop #$%* up and waste a bunch of money without any semblance of a plan. This time I would be patient and move slowly and methodically. We'll see how that goes...

As with many projects, it all started with me scouring craigslist for the right bones--a CB550. Living in SoCal, we are slaves to the highway--so I needed something with enough power but nimble enough so that my small asian body would not look silly in (who am I kidding, I still look ridiculous). Fortunately I found this little fella for $600, so I hooked up a trailer and rolled out to San Diego.




Odometer read 38k miles, she had clearly been left out in the sun, and despite a viable starter--she didnt turn over. While I was apprehensive--I figured...even if this was a total dumpster fire...I could still part it out and make my money back. Interestingly enough it had a 4-into-1 exhaust...the warning label by the fart can was half peeled off but it LOOKS like an OEM from a CB550F? Or it could just be some china exhaust. Fueled by youthful ignorance and...well...arrogance...I figured--I'm not a moron, this couldnt be THAT complicated.

After getting it home, covering the usual water unfriendly prospects, and giving it a light wash and scrubbing. I rolled it into the garage and started to get to work. Basic stuff: wiring loom seemed intact, everything under the headlight was there, all fuses were still good, and while the battery was deader then disco--everything seemed in order.




I went to pop the seat...no luck. The key didnt fit. Apparently the seller swapped the ignition (it was a lien sale, so no surprise there) which was unfortunate as I'd now have to wrangle the seat off. I ordered the correct original key off ebay so that I could use the steering lock in the future--but I was too impatient...I got the seat off by unbolting the seat lock. Took a lot of manuevering, but it can be done.



I figured the carbs were going to be a proper wreck, so I ordered a K&L Pro Rebuild kit and one of those 6Sigma jet kits off ebay. I know its an unpopular modification around these parts to ditch the airbox...but...I'm too stupid to listen to reason and logic from smarter and more knowledgeable people lol. Meanwhile...time to strip the tank and put on new bars.



Also fitted the battery box from Cognito Moto to hold the electronics and new 8cell Antigravity battery.

I took off the carbs and used (x4) magnetic trays to keep everything in order. To my surprise? Not that bad! Bowls were a little dirty but it wasnt anything too terrible! Now to give everything a 15 minute run in the ultrasonic with Berryman carb cleaner!




Clean as far as I can tell!



Few days later this kit from 6Sigma came. Now I was VERY apprehensive about what this was, would these be some dog#$%* jets from china? To my surprise, they had the Keihn logo on them...is it authentic? I hope so. I'm not nearly an expert, but if they ARE it seems like a good deal. I paid about $75 for them and it included 120 and 130 mains and 42 pilots, the same jets ordered from JetsRUs would have costed more than I paid.




WIth the carbs finished, I ordered a set of K&N filters. And set about the next task, the frame. Cutting a frame is always a nerve-wracking feat...theres really no going back. But #$%* it, if I was about to make smart choices I wouldnt have bought a motorcycle in Southern California!




The seat also came in, I bought a diamond stitch seat from Tran over at OCCafeRacer (https://www.occaferacer.com/)--seems like a really good dude and I'm very happy with what I got and the price I paid. If your looking for a seat, I highly encourage you reach out to him--he even includes the lip in the front so you can avoid the unsightly gap between seat and tank. He's also making me a removable cowl, but more on that when it comes.




I peeled back some of the metal to line up the new hoop (courtesy of Carpy's Cafe Racers) with the rest of the frame tubing. You can probably see where I cut a little too deep, this was concerning for me...but I figured it would give me a spot to weld in the slug and this #$%* up might end up giving me better structural integrity (assuming I make good welds).



While I waited for the filters to get it...I decided to start putting the knee dents in the tank. Using the tear drop hammer recommended by...pretty much everyone I'm pretty happy with the dents...but I cant say I'm in love with the little digs. I dont think im going to paint the tank but I'd really like to try to smooth some of those harsh spots out. Maybe some light rubber mallet work will get a better texture.



More to come.

[XC204]

Nice work! Must have taken some worry before the first hammer sack on the tank.

[kenjataimu]

Nice work! Must have taken some worry before the first hammer sack on the tank.

Honestly...still unsure whether I'd do it again if I could lol. The little dings give it character but I waver between liking it and getting irked by it. That said, I can always replace the tank or find a second one to mess with.

[kenjataimu]

Since I started the build, the bike had pretty much always been on the center stand--but when I took it for my first test ride I realized that the center stand was rubbing against the chain! After some research I found that the original exhaust had a little arm that kept the center stand at bay, and since I was using this turn out exhaust I would have to find a way to block the stand. At first I fashioned a little metal bar with a notch, but then I saw a thread where someone used a metal washer and I thought it was a far more elegant approach.





Annoyingly though...this happened after I took my test ride. So...guess its time for new tires and tubes.

[kenjataimu]

Batteries and annoyances.

My initial instinct was to use the smallest battery available which still enabled me total comfort in using the electric start--the Antigravity 8-cell. Naturally I ordered one from Amazon along with an Optimate 3 charger (the brand and model specifically recommended by Antigravity), and figured my favorite online retailer would be a reliable source. First battery came almost dead, the problem with using these lithium-ion (LifePo4) batteries is that if they drop below 12v...they are basically an expensive paperweight. I plugged it into the charger to see if it could be “saved” just out of curiosity...it could not. So I returned the battery to Amazon and elected to have them send me a replacement. The replacement worked...for about 4 weeks (of course it stops working just outside the return window) before it stopped holding a charge. Knowing that these bikes don’t always have the most trustworthy electronics, I went about testing for parasitic leaks and poor grounds--nothing. So I contacted Antigravity to have the battery warrantied--and about a week later--a new battery showed up! I’m pretty happy with Antigravity’s commitment to customer support and I recommend anyone whose on the fence about them give them a shot. Just dont buy them from Amazon.



While waiting for the battery to get back to me, I wanted to ride...but I didnt have the capacity to fit a big ass battery so I scored the internet to see what other options I had for a small battery I could pick up locally that would work in the mean time (and also serve as a bench testing battery). I watched the video posted by Common-Motor Collective and he brought up the interesting idea of using an SLA battery. This is how I ended up picking up a Duracell Ultra 12v 6.5aH AGM SLA battery (https://www.batteriesplus.com/product-details/sealed-lead-acid/battery/duracell-ultra/durhr12=6.5fr)



I was apprehensive that it wouldnt be sufficient CCA to turn over the electric start, but to my surprise--it works! It crowds the battery box and I had to make new battery leads, but it was a worthwhile exercise. I picked up a couple feet of red and black 10ga wire from home depot as well as some female spade and ring terminals, and in about 20 minutes I had the battery wired up and running. Heres a photo of the battery box with the Duracell. I think I’m going to just run this for a bit even though my antigravity replacement has arrived just because im too lazy to touch anymore electronics for a while.

[XC204]

That's looking good! Glad some one had a  use for the center stand stop idea 💡
Gary

[kenjataimu]

I bought a second used triple tree off ebay, stripped the paint, shaved off the handlebar mounts with an angle grinder, then evened it out with a flap disk. I drilled out holes for the indicators (originally I drilled 4...but then i realized I didnt space them out properly...because i am idiot--so I just drilled 5 holes and figured id throw in a white light...which i could find use for later). I tossed in the indicator lights I had lying around, but I'll need a yellow to round out set.



This is just to map out my progress, but ill need to do a full polish job and install the indicator when it arrives.