Author Topic: Another project-1976 Honda CB550K  (Read 16338 times)

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Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #75 on: January 10, 2024, 08:34:40 AM »
Were you able to “save” the retainer? I keep one on the shelves, just in case!

Yes, but had to perform surgery on it for a few minutes with a file.

Offline BenelliSEI

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Re: Another project-1976 Honda CB550K
« Reply #76 on: January 10, 2024, 09:49:11 AM »
Were you able to “save” the retainer? I keep one on the shelves, just in case!

Yes, but had to perform surgery on it for a few minutes with a file.

Well done! I find if there is a new one sitting on the shelf, the old ones stand a better chance…….

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #77 on: January 10, 2024, 12:30:31 PM »
Another day, few more items taken care of....

Wheel bearings in, spokes laced to new rim......truing to commence Friday..


Offline Mark1976

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Re: Another project-1976 Honda CB550K
« Reply #78 on: January 10, 2024, 02:16:15 PM »
   Looks great!!!
Start with the end in mind...

Offline Stev-o

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Re: Another project-1976 Honda CB550K
« Reply #79 on: January 11, 2024, 07:36:58 AM »
Well done, nothin like a freshly rebuilt wheel!
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #80 on: January 11, 2024, 12:29:18 PM »
Why does the 2nd one always go smoother....I don't know, but this one trued up easy, only 2-3 hours on it.

Tire installed......and put aside...

Will probably take off front forks next for cleaning/polishing and checks, replace seals, replace bent fork ears (Thanks again Mark1976).

Offline Mark1976

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Re: Another project-1976 Honda CB550K
« Reply #81 on: January 11, 2024, 05:40:57 PM »
   The first wheel's your introduction and education, everything after that, 'is a piece a cake.'
And your welcome...
Start with the end in mind...

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #82 on: January 12, 2024, 12:46:47 PM »
Performed more work today, lots of cleaning.

The front end had a caliper leak, as well as both fork seals, and the whole front was a baked on greasy mess.

Repainted the front caliper, looks better.

Removed the forks, but had issues.  The right fork had to be beat out with a dowel and hammer because of rust.  Both lower forks are soaking in a bath of dawn dish soap hoping it will dislodge some of the grease.

Also screwed up the same right fork leg trying to get the allen bolt out of the bottom.  I guess my tool was not seated good when I started up the drill driver.  Other side came loose with no issues.  After trying again I rounded out the inside of bolt.

Assume only option now is to drill ?

Also think I need to replace the steering stem bearings, I think I can feel a notch while turning back and forth, but will investigate more.

Is there a process for disconnecting all the wires in the headlight bucket?

Moving on....


Offline BenelliSEI

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Re: Another project-1976 Honda CB550K
« Reply #83 on: January 12, 2024, 01:04:42 PM »
 Drill the head of the bottom cap screw off. Once you get it apart, it will undo easily with vice grips on the remaining shank. The wires do come out of the headlamp! Start with the smallest (speedo and tach light feeds) and as you go along it makes space. Disc looks nice!

Offline BenelliSEI

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Re: Another project-1976 Honda CB550K
« Reply #84 on: January 12, 2024, 01:09:59 PM »
Before you drill the head off that bottom cap screw, try this:

I have a set of TORX driver bits that fit in my impact gun. If you have some, find one that almost fits and then beat it into the rounded hole. I often get them jammed in tight enough the gun will pop it loose. Then order a new bolt!

Offline newday777

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Re: Another project-1976 Honda CB550K
« Reply #85 on: January 12, 2024, 01:38:36 PM »
Before you drill the head off that bottom cap screw, try this:

I have a set of TORX driver bits that fit in my impact gun. If you have some, find one that almost fits and then beat it into the rounded hole. I often get them jammed in tight enough the gun will pop it loose. Then order a new bolt!

Ditto
Stu
Honda Parts manager in the mid 1970s Nashua Honda
My current rides
1975 K5 Planet Blue my summer ride, it was a friend's bike I worked with at the Honda shop in 76, lots of fun to be on it again
1976 K6 Anteres Red rebuilding project, was originally my brother's that I set up from the crate, it'll breath again soon!
Project 750s, 2 K4, 2 K6, 1 K8
2008 GL1800 my daily ride and cross country runner

Prior bikes....
1972 Suzuki GT380 I had charge of it for a year in 1973 while my friend was deployed and learned to love street riding....
New CB450 K7 after my friend returned...
New CB750 K5 Planet Blue, demise by ex cousin in law at 9,000 miles...
New CB750 K6 Anteres Red, to replace the totaled K5, I sold this K6 at 45k in 1983, I had heavily modified it, many great memories on it and have missed it greatly.....
1983 GL1100A, 1999 GL1500 SE, 1999 GL1500A

Offline Mark1976

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Re: Another project-1976 Honda CB550K
« Reply #86 on: January 12, 2024, 01:43:29 PM »
  The wires do come out of the headlamp! Start with the smallest (speedo and tach light feeds) and as you go along it makes space.
+1
Its just easier than pulling it apart and then trying to put it back together....
Start with the end in mind...

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #87 on: January 12, 2024, 02:00:13 PM »
T45 for the win......

Thanks John for the tip...

Clamped in the bench vise, beat in the T45, heated it up, put the 1\2" air gun on it this time, backed right out...

Now I can sleep tonight......

Offline grcamna2

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Re: Another project-1976 Honda CB550K
« Reply #88 on: January 12, 2024, 02:03:42 PM »
T45 for the win......

Thanks John for the tip...

Clamped in the bench vise, beat in the T45, heated it up, put the 1\2" air gun on it this time, backed right out...

Now I can sleep tonight......

excellent  :)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline BenelliSEI

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Re: Another project-1976 Honda CB550K
« Reply #89 on: January 12, 2024, 02:56:17 PM »
“Brute force and ignorance” triumphs again!

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #90 on: January 12, 2024, 03:27:37 PM »
“Brute force and ignorance” triumphs again!

Indeed  ;D

Offline seanbarney41

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Re: Another project-1976 Honda CB550K
« Reply #91 on: January 12, 2024, 05:10:18 PM »
Before you drill the head off that bottom cap screw, try this:

I have a set of TORX driver bits that fit in my impact gun. If you have some, find one that almost fits and then beat it into the rounded hole. I often get them jammed in tight enough the gun will pop it loose. Then order a new bolt!
Yep!  I have had this work a few times.
If it works good, it looks good...

Offline grcamna2

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Re: Another project-1976 Honda CB550K
« Reply #92 on: January 12, 2024, 05:20:44 PM »
I've removed damper rod allen bolts before after stripping the 6mm or 8mm size by using an SAE allen socket the next size up.
I have a few sets of them and was able to take a long enough SAE allen wrench and hammer it in,then use a 1/2" dr. electric impact and use the same damper rod bolt over,if needed.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #93 on: January 13, 2024, 12:07:04 PM »
Front forks apart and somewhat cleaned.....will spend more time cleaning/sanding and polishing fork legs next week.

What do most people do at the top of the forks where rusty?  clean/sand and paint?


Having trouble getting the piston/pad out of caliper.  I tried my grease gun but does not connect with the fitting on the end of gun.  Tried a few bursts of air but no luck.  Letting it soak with PBblaster for now.
« Last Edit: January 13, 2024, 12:14:08 PM by denward17 »

Offline grcamna2

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Re: Another project-1976 Honda CB550K
« Reply #94 on: January 13, 2024, 02:19:41 PM »
Den,I hope you can get the caliper piston to release using the master cylinder/brake fluid.

I think you should have a close look at your fork tubes,in the 'areas of travel' i.e. the parts of fork tubes that make contact inside the fork 'lowers'.
You can inspect the upper parts which are in contact with the fork seals to see if there's rust or pitting from flying rocks,etc. which shoots off the back of vehicle's tires and hits that part of the fork 'travel area' which can make your seals tear and leak later on.
I wouldn't sand down a fork tube,especially in the 'travel areas' and the part of the tubes which are down inside the lowers;sanding down a fork tube will reduce it's O.D. and cause a loose fit inside the lowers which will will cause the front-end to wobble  :o 
When you find nicks in the seals area,you can get a small piece of like #400 sandpaper and then only use your fingernail to soften Just the sharp edges around the small nicks to keep from cutting your new fork seal's.

I recommend using a micrometer or calipers and measure the O.D. of the full 'travel areas' of each fork tube to see if the O.D. is not below the minimum O.D. according to your shop manual specs.  ;)  I hope your fork tubes 'pass muster' in those wear-areas of measurement,otherwise it's best to replace the tubes with a fresh pair.
Depending on the amount of mileage(wear between them)and how often the fork oil was changed... also take a dry-fit of both the 'lowers' and fork tubes to see if there's any 'wiggle'/movement between them. The 'lowers' being aluminum wear also.
« Last Edit: January 13, 2024, 02:28:31 PM by grcamna2 »
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #95 on: January 13, 2024, 04:35:52 PM »
Good points, will look into the fork pipes, but at quick glance I don't see specs for the OD of the pipes.

Offline BenelliSEI

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Re: Another project-1976 Honda CB550K
« Reply #96 on: January 13, 2024, 05:09:09 PM »
Dennis……. With 12K miles those tubes should be just fine. The wear should be negligible. Are they straight? Really polish the area where the fork seals run. It’s pretty easy to see where they travel. Nothing aggressive, just polish. That area is covered by the gaiters so there should be no stone damage? Smooth the part that slides into the trees with a light grade of paper. No one sees them, covered by the fork ears. Make them easy to slide in and stop. The bottom part should just need a good scrub.

As mentioned above, the aluminum bottoms wear faster, so try the “wiggle test” suggested, for sure. Again, with only 12K mileage, it should all be fine.
« Last Edit: January 13, 2024, 05:17:14 PM by BenelliSEI »

Offline grcamna2

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Re: Another project-1976 Honda CB550K
« Reply #97 on: January 13, 2024, 05:27:26 PM »
Dennis……. With 12K miles those tubes should be just fine. The wear should be negligible. Are they straight? Really polish the area where the fork seals run. It’s pretty easy to see where they travel. Nothing aggressive, just polish. That area is covered by the gaiters so there should be no stone damage? Smooth the part that slides into the trees with a light grade of paper. No one sees them, covered by the fork ears. Make them easy to slide in and stop. The bottom part should just need a good scrub.

As mentioned above, the aluminum bottoms wear faster, so try the “wiggle test” suggested, for sure. Again, with only 12K mileage, it should all be fine.

I've use grey/fine Scotch Brite pads(grey is the least abrasive)to polish the tubes.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline grcamna2

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Re: Another project-1976 Honda CB550K
« Reply #98 on: January 13, 2024, 05:41:29 PM »
Good points, will look into the fork pipes, but at quick glance I don't see specs for the OD of the pipes.

I have a shop manual in storage Den;I can go there and look up the correct outside mm diameter of the fork tubes for you if no one else here has the info readily available. Let me know  ;)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline denward17

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Re: Another project-1976 Honda CB550K
« Reply #99 on: January 13, 2024, 07:05:12 PM »
Good points, will look into the fork pipes, but at quick glance I don't see specs for the OD of the pipes.

I have a shop manual in storage Den;I can go there and look up the correct outside mm diameter of the fork tubes for you if no one else here has the info readily available. Let me know  ;)

I saw on Forks by Frank's website that they should be 35mm, that's all I could find so far.

I have a soft copy of a 500/550 service manual, in the technical data section it only lists the free length of the springs.