Topic: 76 550F Basketcase Build

[AllGasNoBrake]

Joined here shortly after buying this project and thought I should document my progress (i.e. frustrations) somewhere as this has been a fun and challenging project that I plan on selling once completed.

1976 CB550F
Found someone elses project on Craigslist that they gave up on and it seemed like the perfect opportunity to use up what little free time I had and give me an excuse to be in my garage. I’ve ridden/worked on sportbikes/dirtbikes/cars over the years, but this will be the biggest project I’ve undertaken thus far.

Starting state:
After unloading 10+ mostly unmarked boxes and a frame I tried to inventory and organize as best as possible, but there are quite a few unidentified pieces that remain and I haven’t even cracked open the engine. Supposedly it needs a new cam, but I have boxes with rockers and pistons and don’t know yet what’s inside and what’s a spare. The previous owner had the engine and carbs vaporblasted as well as the wheels and misc items powdercoated. I’ve spent a lot of time and wire wheels removing powdercoat from areas it shouldn’t be in to make things fit.


Current state:
Somewhat of a roller at this point. I’ve had little time to work on this project but every so often I get a spur of motivation and multiple boxes from 4into1 and eBay to keep me going. I’ve assembled, disassembled, and re-assembled this


Goal state:
The end goal is a minimalist cafe/brat style bike that I will sell shortly after completing. Considering the state it was in, a restoration was out of the question, and if I put enough time/money/effort into a project I want it to be one of a kind and look the way I’ve always imagined.

What I’ve done so far:
Removed surface rust and painted frame
Replaced wheel bearings/seals Front and Rear (twice on the rear)
Upgraded head/stem bearings to sealed
Chopped the rear end (hoop needs welded)
Installed clip-ons, grips and new controls (then reverted to stock controls)
Ran new brake lines and clutch/throttle cables
Rebuilt and installed front brake
Rebuilt 1 carb (every nut and bolt in the carb assembly was removed)
Assembled rear hub/brakes
Laced/trued wheels (wow was that not fun)
Mount/balanced tires
Rebuilt forks
Installed dyna coils
New rear shocks
Installed swingarm bushings
Replaced regulator/rectifier with a new combined unit
Replaced flasher relay for a new LED compatible one
Purchased a lot of new tools

What I need to do (that I can remember):
Finish carb rebuild
Decide on jets before finishing carb rebuild (5,280ft elevation, free flow exhaust, velocity stacks or intake box)
Finish running the wiring
Build new electronics tray
Paint (tank, likely a chopped but paint matched front fender)
Engine - Install new cam (stock was in bad shape, ordered a few used to find best condition)
All new gaskets
Install Dyna ignition
Run rear brake controls
Install 4 into 1 exhaust it came with, decide if I like it or not
Install new clutch
Install headlight

Still deciding on:
Gauges and indicator lights setup
550/650 cam (whichever I find in the best condition)
Turn signals (possibly bar ends on the front, integrated in the hoop for rear)
Rear brake light
Color for paint
Rearsets
Seat (this one was a freebie)
Gas tank - stock or slightly different
Pods/Stacks/Filter box setup (I know the right answer)
Keep stock headlight or change out

What I’ve learned so far:
More than I can recall, mostly thanks to this site
Never buy someone else's project
When it doesn’t fit, stick it in the freezer and get out the heat gun
Label every single nut and bolt you remove

[Alan F.]

I love basket case builds, make it yours man! There are no rules.

I've got a CB650 cam going cheap if interested.

[newday777]

It sounds like you have a good plan in place. The 550 is a great bike to build upon and yes the 650 cam will add lots.

[AllGasNoBrake]

Would have taken you up in the 650 cam, but I already had a 550 cam ready to go. If I have to tear it down again that could be an option.

Just a quick update:
Added bar end turn signals (cheap from Amazon, judging by the wire they came with they will be broken and replaced with bar end mirrors before long)
I cut off a few more tabs as well as the middle seat bar to make room for the battery and electrical box
Started teaching myself to weld, welded slugs into the rear and have began cutting the box (on ver 3 at this point)
Got a battery (Motobatt)
Bought new Jets to finish the carbs (115 & 40)
Purchased Slip Stream Rearsets (realized at my height the stock position would be awkward)
550 cam is installed
New spark plugs gapped and installed
Misplaced a box that I swear had an oil filter bolt, bought a new one, realized there's a few pieces from the lower section of the oil filter cover I'm also missing.
New rear shocks (4into1 black)
Installed rockers




Cam cover is ready to go on, just want to add some oil in addition to the assembly lube but to prevent oil leaking onto my carpet I need to find/order the oil filter pieces I'm missing.
had 2 starters, both bench tested and worked but one has some gnurling on the teeth so I'm using the better one.

Hoping to get more done next week. Finish the electrical box, cut a seat pan, weld a new crossbar on the seat, cut and weld the hoop.

[Godffery]

 Just checked out your build thread.  The progress is coming along nicely!  Thanks for posting the project!

 Regarding your Gauge options; 
I have found SpeedHut Gauges to be well built and reasonably priced. https://www.speedhut.com/
Perhaps not quite MotoGadget level but also not $uper $pendy! 

 BTW; hit me up if you would like to update your front Brakes, I make components that dramatically improve the stock parts.

[seanbarney41]

Please, before more effort may be misguided, you may want to check if the seat hoop can contact the rear wheel.  This is done properly by removing springs from shocks and compressing shocks to the bump stop.

[AllGasNoBrake]

Just checked out your build thread.  The progress is coming along nicely!  Thanks for posting the project!

 Regarding your Gauge options; 
I have found SpeedHut Gauges to be well built and reasonably priced. https://www.speedhut.com/
Perhaps not quite MotoGadget level but also not $uper $pendy! 

 BTW; hit me up if you would like to update your front Brakes, I make components that dramatically improve the stock parts.

Thanks for the gauge suggestion! Definitely looking for something that won't break in a few weeks off Amazon but also that won't break the bank. I'll check out the brake upgrades once I see how stock performs, I have another disc and caliper but am not committed to going dual disc so this could be a sensible upgrade.

[AllGasNoBrake]

Please, before more effort may be misguided, you may want to check if the seat hoop can contact the rear wheel.  This is done properly by removing springs from shocks and compressing shocks to the bump stop.

Once I cut the hoop down I have the slugs welded on to test the clearance before final fit. The hoop is slightly upswept to help, but this is a legitimate concern with depth of the battery/electrical box and the fact that I'm 200lbs. Thanks for the tip.

[Stev-o]

I restored a "basket case bike" a few years ago, they can be frustrating, but you sure learn a lot about the bike.

FYI - are you aware of the "rubber band trick" when installing the head cover on the motor?

To ensure you dont bend any valves, back the rocker arm tappets all the way out as well as use the rubber band trick to hold the rocker arms up.

[Godffery]

Just checked out your build thread.  The progress is coming along nicely!  Thanks for posting the project!

 Regarding your Gauge options; 
I have found SpeedHut Gauges to be well built and reasonably priced. https://www.speedhut.com/
Perhaps not quite MotoGadget level but also not $uper $pendy! 

 BTW; hit me up if you would like to update your front Brakes, I make components that dramatically improve the stock parts.

Thanks for the gauge suggestion! Definitely looking for something that won't break in a few weeks off Amazon but also that won't break the bank. I'll check out the brake upgrades once I see how stock performs, I have another disc and caliper but am not committed to going dual disc so this could be a sensible upgrade.

 Okay Groovy.
Meanwhile if you want to check out the goods, here are a couple links for you.    https://godfferysgarage.com/ or https://www.instagram.com/godfferysgarage/ or https://www.facebook.com/godfferysgarage
   (Drilled & Thinned Rotors, Lightweight Phenolic Caliper Pistons, Updated Calipers, Speedo & Tach blanks, Etc.)

[AllGasNoBrake]

I restored a "basket case bike" a few years ago, they can be frustrating, but you sure learn a lot about the bike.

FYI - are you aware of the "rubber band trick" when installing the head cover on the motor?

To ensure you dont bend any valves, back the rocker arm tappets all the way out as well as use the rubber band trick to hold the rocker arms up.

Learning experience for sure.. Googling to find what goes where and then looking through boxes for it only to end up on eBay trying to find it by part number. Frustrating at times but when you make even a small amount of progress it makes up for it. I've been very close to buying another one (already assembled) just to use as a reference!

Picked up rubber bands this week. I saw that tip somewhere and realized that would be way easier and without the risk of bending anything.