Topic: Another project-1976 Honda CB550K

[willbird]

Finished stripping the paint, sanded with 100 grit and then 220 grit with palm sander.

Need to finish up going around the edges by hand, that can't wait another day or so.

Tried to use a c-clamp and a 6 penny nail to push the cap pin through, but the nail just bent , also need another pairs of hands to help hold.

I do not remember the dia of that pin but Mao mart has a set of Stanley pin punches that work well and are cheap enough($20) to just toss and buy a new set once they get a little messed up.

https://i5.walmartimages.com/asr/aef46ba7-75d9-4c28-ab96-28063917381c_1.81f77e32daba3c380bc6614281d89b5a.jpeg?odnHeight=717&odnWidth=717&odnBg=FFFFFF

[BenelliSEI]

Drill off the “head” and push it through. The other end has been punched and can be swollen enough that it’s best to reverse it out.

[denward17]

It runs......

https://photos.app.goo.gl/MrRSXQ8W4VYKXLF58

I do have a fuel leak, #3 float bowl gasket, but further investigation is needed.
Have an exhaust leak as well, will tighten up the flanges.

Checked dynamic timing, it was fine, adjusted carb sync as well.

Pulling carbs off in my future I'm afraid.  But it did idle well.

[newday777]

It runs......

https://photos.app.goo.gl/MrRSXQ8W4VYKXLF58

I do have a fuel leak, #3 float bowl gasket, but further investigation is needed.
Have an exhaust leak as well, will tighten up the flanges.

Checked dynamic timing, it was fine, adjusted carb sync as well.

Pulling carbs off in my future I'm afraid.  But it did idle well.

Congratulations on getting it running Den

[Mark1976]

   It lives!!!!!!!!

[BenelliSEI]

Good news. Well done!

[seanbarney41]

...recently discovered that dropping the float bowls on a 550 can be done with a shorty screwdriver with the carbs in situ.  I wouldn't call it easy?...but I would definitely call pulling and installing those carbs HARD.

[denward17]

Not much to report....

Have been troubleshooting a slow/non start issue and it appears to be the starter, so got a used one ordered.

Went ahead and took the carbs back off to check all bowl gaskets (had a leak), and this time will perform a clear tube test.  I ordered a couple of the drain hose adapters from Z1enterprises, hope they will work.  My drain screws are 6mmx.75 pitch, these are just listed as 6mmx .7, so will see.

https://www.z1enterprises.com/fuel-level-gauge-tool-kawasaki-suzuki.html

Will not be doing much over the next couple of weeks due to family priorities.

[denward17]

"New" used starter has arrived and testing on the bench it appears to work, it really jumps when I touch the jumper cable to it, unlike the original one.

Can't test on the bike yet as I have the battery box removed along with the carbs. 

Will be replacing all of the Honda o-rings on the float bowls with aftermarket float bowl o-rings that come shaped like the bowls.  Will make sure to test longer this time with gas before installing.

[RAFster122s]

...recently discovered that dropping the float bowls on a 550 can be done with a shorty screwdriver with the carbs in situ.  I wouldn't call it easy?...but I would definitely call pulling and installing those carbs HARD.

Can change them to a socket head screw and make it much easier too domed socket head screws are stealthier...

[RAFster122s]

Find a starter and generator and alternator shop local to you and see if they can rewind your starter and how much ... They will change out bushes or bearings and springs and brushes ano rings and clean comm and do any mods or work on it as required.
A used starter is likely cheaper but a properly rebuild, remanufactured is better...
Used is likely to last you 20 years so that's hard to beat

[denward17]

Trying to get this tank finished up and ready for primer.

Need to go over it again with 220 or 320 again today, hopefully can put some primer on it by early next week, but we have some rain showers for a couple of days.

Waiting on float bowl o-rings and clear tube tools to finish up carbs (hopefully tomorrow).

Received tank decals from https://cbdecals.afegraphics.com/............ they look nice.
Received paint from 66 Auto color.......

[denward17]

Received the float bowl gaskets from PartsNMore, they are too small, not even close to fitting properly.  These are the ones I ordered:

Float Bowl Gasket
#20-8032 | Honda CB550K (1974-1976)
Float Bowl Gasket

So I found out via email, that part# 20-5022 were the correct ones, I asked them to correct the website.

I did go ahead and order these to have as backups:
Float Bowl Gasket
#20-5022 | Honda CB550K (1974-1976)
Float Bowl Gasket OEM Ref # 16019-024, 16010-323-315, 16010-323-004


I had ordered a few months ago the Honda o-rings, discovered that I pinched 2 of them during install a few weeks ago.  My bench test did not reveal any leaks at the time, but I only let it sit with gas for about 5 minutes or so (lesson learned).

Today I put those 2 o-rings in the freezer for about 2 hours after drying out overnight.  I used a dab of grease in all 5 corners to help hold them in.  I re-installed all 4 o-rings with the grease.  Let them sit for about 30 minutes with gas this time, and moved them from side to side, no leaks.

Also performed the clear tube test and all looked fine to me, so I installed the carbs back on the bike.

Next up, install battery box, battery, and getting my tank primer coated (hopefully weather will cooperate, very windy here lately).

[BenelliSEI]

Nice work on the carbs. They’ll work great!

[Mark1976]

One thing at a time, also, hows the tank prep coming along.

[denward17]

One thing at a time, also, hows the tank prep coming along.

Tank is ready to be primed and inspected more thoroughly, waiting for the wind to die down some, or may just end up priming in the garage, but hate to do that, requires more setup/cleanup.

Also tested "new" used starter this morning, it works like it should now, engine will spin quite good with new battery.

[grcamna2]

One thing at a time, also, hows the tank prep coming along.

Tank is ready to be primed and inspected more thoroughly, waiting for the wind to die down some, or may just end up priming in the garage, but hate to do that, requires more setup/cleanup.

Also tested "new" used starter this morning, it works like it should now, engine will spin quite good with new battery.

I understand your struggle.
I need a full inside spray booth w/ all the proper gear.

The weather here has been raining/storming and blowing ever since last year 
This area is normally a dry,sunny place that's very nice to spray paint outside,except for some wind.

[denward17]

Patience got the best of me.....

I set up just before the garage exit and was able get my tank primed with etching primer, put on 4 coats, 3 underneath.

After sanding and inspecting next week, will spray with the black primer that is the base before color is sprayed.

[Mark1976]

Patience is your friend when painting. It's all in the prep. Paints only as good as what's underneath it. Looks pretty good so far.

[RAFster122s]

^I believe it was for most of its life, as there is not much rust, just some near where the battery apparently leaked onto the frame.

If you pull the battery box and other things in the way you can use some paint stripper, naval jelly, they spay paint after masking with newspaper or plastic where you don’t want overspray. The acid damage needs neutralized well so the rust doesn’t progress into a problem wheel has to come off etc…
David

[denward17]

Caught a break with weather, low wind, low humidity, so scuffed up the tank and side covers and used the black primer.

If weather holds out this week plan to shoot the base color and 1K clear.

Will come back after a week or so and install decals, shoot 2K clear.

I can't make up my mind yet about the black cleats, may leave them off.

[denward17]

One thing I found out today using this Kandy color, you cannot have any primer sanded through, the whole panel has to be black with this type of paint and color.

I test painted 1 side cover today, and had a small spot behind where the badge goes that I sanded too much and removed the black primer, so then decided to check the other side cover and tank.  I discovered I had 2 places on the the other side panel, and 1 place on the tank that I sanded through the black primer.

So I need to clean up the one side cover and black prime again, and of course re-prime the tank and other cover; this time I will not sand as much.

Pic of test card spray, black primer, kandy color and then 2 coats of 1k clear.

[BenelliSEI]

Lot’s of work! Looking good.

[Mark1976]

   Why not shoot 2 coats of a gloss black as your base coat, then follow with your candy color coat. Just a  suggestion..

[denward17]

   Why not shoot 2 coats of a gloss black as your base coat, then follow with your candy color coat. Just a  suggestion..

I actually thought about that......and may do it.