Author Topic: Resto Honda CB500K1 1972 (Read 3715 times)

CB500K1 · « **on:** September 11, 2021, 10:26:23 PM »

I bought this bike in May and my first intention was to get it back on the road but it's now turning into a resto.
I found this section on the SOHC/4 forum only recently so I started a blog about the resto before.
https://hondacb500k1.blogspot.com/
I'll try to put the updates on here as well from now on

Cheers from downunder

CB500K1 · « **Reply #1 on:** September 11, 2021, 10:27:33 PM »

I also tried to upload some pics but apperently they're to big..
I'll give it another go in a min

CB500K1 · « **Reply #2 on:** September 11, 2021, 10:30:28 PM »

Second attempt..:0

newday777 · « **Reply #3 on:** September 12, 2021, 02:09:30 AM »

Well done and great write ups in your blog.
I had a 67 122S back in the winter of 1974. A fun car to drive in the snow.

Little_Phil · « **Reply #4 on:** September 12, 2021, 06:40:39 AM »

Yes interesting write up so far. Particularly the detail on the paint mixing and spraying. I've had two done by Menno in Germany, one candy gold and one candy ruby red.
Notice the clips you are using for the tank badges are the side cover ones. Usual procedure for tank badges AFAIK is to offer up the badges to the tank and shape to make sure they follow the contour. (I have a piece of wood with a curve so that I can press into to avoid sharp bend) Insert the clips into there location on tank and then press badges all the way home.
Will follow with interest.

CB500K1 · « **Reply #5 on:** September 29, 2021, 02:57:14 AM »

Thanks guys.
The last couple of weeks have been very busy at work so I could only do little bits on the bike. One of the things I did was taking the front fork legs apart. The part of the inner tubes hidden inside the ears were badly rusted which made it difficult to get 'em out. The old fork seals wouldn't came out whatever I tried.. completely stuck..
So today I took some old metal bits I had laying around in the shed and made a "fork seal remover tool". I took a washer that was almost the same size as the fork seal, shave two sides of and bolted it on a threaded rod. Anyway I'll upload some pics of the fork seal device, it worked like a charm and they came out in 10 sec.

CB500K1 · « **Reply #6 on:** September 29, 2021, 03:52:57 AM »

some pics..

CB500K1 · « **Reply #7 on:** September 29, 2021, 04:00:59 AM »

1 more

CB500K1 · « **Reply #8 on:** September 29, 2021, 04:19:08 AM »

Another job I took on last weekend was stripping the frame back to bare metal. I started with paint stripper, wiped it off with some steel wool and the next day I used the angle grinder with a brush wheel (x4) to get all the old paint and surface rust off. It took me close to six hours.. Time for some etch primer and black two pack paint:)

CB500K1 · « **Reply #9 on:** November 12, 2021, 04:47:31 AM »

Etch primer and 2-pac paint all done.. looking great. The only thing that bothers me a bit is the fact that the frame number stamp is so shallow that it's kinda hard to read with the new paint on top. I'll probably end up scratching it out..hmmm
Anyway here're some more pics: https://hondacb500k1.blogspot.com/2021/11/stripping-and-painting-frame.html

Stev-o · « **Reply #10 on:** November 12, 2021, 07:24:38 AM »

Nice work!

BenelliSEI · « **Reply #11 on:** November 13, 2021, 02:07:22 PM »

All looks very smart. When you paint the front disc, how do you mask the rivet heads??

CB500K1 · « **Reply #12 on:** November 13, 2021, 10:25:53 PM »

Tnx. I just mask them with good quality masking tape. When you take the tape of after spray painting you can touch up around the rivet heads with a very small brush.

CB500K1 · « **Reply #13 on:** December 11, 2021, 09:30:37 PM »

The last couple of weeks I've been "fighting" with the rear wheel bearing retainer and other rear wheel gremlins... It was very hard to remove the retainer without the special tool but after a couple of trial and errors I got it loose. Also fitted new tyres; Dunlop Roadmaster TT100 GP. I kinda underestimated the amount of work that goes in a rear wheel :O
Anyway, here're some pics: https://hondacb500k1.blogspot.com/2021/12/replacing-rear-wheel-bearings-brake.html

RAFster122s · « **Reply #14 on:** December 11, 2021, 10:29:01 PM »

Nice work...were the old bearings bad? Or, did you just want to replace them? DSS has a rear wheel bearing retainer tool,not cheap though. I bought one several years ago but had to return it, the manufacturer was off a bit and it didn't quite fit the old or aftermarket retainer. They sourced a new old stock retainer suspecting the retainer. I had told them it was an issue for both, but they had to verify for themselves. They worked with the tool supplier to get it corrected. At the time NOS retainers for the 550 and 500 were hard to come by... They pulled the tool from their catalog until it was reworked to fit properly.
I was able to get it to engage 3 of the four holes, enough to work on the hub.
At the time the tool was around $60 if I remember correctly.

CB500K1 · « **Reply #15 on:** December 11, 2021, 11:05:55 PM »

Yeah they were bad. I searched for the tool and couldn't find anything under a 100 aud. I also didn't wanna wait weeks to get it. Good job you got them fixing that tool

CB500K1 · « **Reply #16 on:** January 29, 2022, 01:36:46 AM »

The last couple of weeks I've been working on the engine. 0.25 oversize pistons are installed, new cam chain tensioner and slipper, new cam chain, the engine painted with dupli color D1615 etc. But when I wanted to put the head back on I discovered that one of the dowel pins that go between the head and barrel for alignment was damaged during disassembly, you cant't see it with the naked eye but it wasn't perfectly round anymore and didn't fit in its hole. I tried to reshape it but that stretched the metal. not a big deal as the cost only a couple of dollars but they are hard to get quick. So I ordered 2 new ones and now have to wait 2 weeks before I get them. I'll update when I get them..

I also worked on the clutch bits and replaced the gear shift spindle. Does anyone know where to get normal clutch springs? Everywhere I look they offer you the heavy duty (way longer) springs that I don't wanna use..
Anyway here are some pics of the clutch job https://hondacb500k1.blogspot.com/2022/01/honda-cb500k1-clutch-and-gear-shifter.html

Little_Phil · « **Reply #17 on:** February 01, 2022, 09:56:15 AM »

Been reading back and the one thing that is never mentioned is the 500K0 K1 fork damper. The item is sealed and I found some have survived better than others. Anyone ever split one?

CB500K1 · « **Reply #18 on:** February 05, 2022, 04:14:49 AM »

Hi Phil, I don't think you can take that inner damper rod apart. According to the parts manual it's just one piece. The only seal that's used goes into the top outer leg underneath the cir-clip and that seals the oil in which the damper travels.

Little_Phil · « **Reply #19 on:** February 05, 2022, 10:05:39 AM »

That's right. Just wondered what the sliding seal was inside.
I had two spare dampers and found that some were better than others. Just bolted the damper in the fork leg. Filled with oil and pulled up/down on the rod. Chose the best two.
Later bikes (550s) have accessible and replaceable seal.

CB500K1 · « **Reply #20 on:** February 12, 2022, 01:05:04 AM »

Last week I got the new dowel / knock pins that go between the barrel and head for alignment. SO this morning I got up early whilr it was still nice and cool in the shed and fitted the head with new nuts and torqued them down to 22 Nm (16 foot pound) Next step was fitting the cam and camchain over the sprocket. It was a bit of a struggle to get the sprocket with camchain back on the cam but with a thick piece of wire I managed to pull it high enough so I could carefully tap it back in place with a rubber mallet. Everything moves smoothly, the only worry I have is that the camchain appears to be very tight. It's a new camchain but I'm wondering if this is normal? Anyone with installing new cam chain experience on this forum? Cheers

CB500K1 · « **Reply #21 on:** February 12, 2022, 01:18:01 AM »

I added some pics but don't know how to make them visible in the post. They can be downloaded though

MauiK3 · « **Reply #22 on:** February 12, 2022, 06:59:41 AM »

Nice project
When I paint discs I press tape around the heads and take a pointy Xacto knife and trim around them.

Stev-o · « **Reply #23 on:** February 14, 2022, 03:09:15 PM »

Quote from: CB500K1 on February 12, 2022, 01:18:01 AM

I added some pics but don't know how to make them visible in the post. They can be downloaded though

I think that type of file [heic] cannot be used, your earlier post had .jpg's

CB500K1 · « **Reply #24 on:** March 04, 2022, 02:15:34 AM »

Yeah must be my new phone

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Author Topic: Resto Honda CB500K1 1972 (Read 3715 times)