Author Topic: My $300 77 CB550F Project  (Read 8689 times)

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Offline chesterburnet111

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My $300 77 CB550F Project
« on: January 31, 2024, 02:20:52 PM »
I've been trying to join this forum for 2 years but I kept getting the question wrong and couldn't get joined up. I tried again and they asked me an easier question. My build started a while ago so I'll try to catch my progress up. Looking forward to the feedback.

My every day bike is a 2019 MT10 which I've done aftermarket suspension on and is the motorcycle love of my life. I've always leaned towards these type of motorcycles. I owned motocross bikes until I was almost 40 and then stopped riding for 20 years. Now I've owned 5 motorcycles since 2016. When I was a kid I liked British bikes and had a clapped out BSA 350 and trying to keep that running left me to admire British bikes from afar. Of all of the traits that are important in cars and motorcycles, reliability is number 1.

I was never a Harley guy but the XR750 flat tracker when came out when I was 13 and I thought it was the coolest motorcycle I had ever seen. About 10 years ago I got the idea to build one for the street but they just seemed to be so far away from the performance I want out of a motorcycle. The bat#$%* crazy prices people were asking for old Japanese used bikes made me think that t was impossible to find a decent one but I kept checking Craigslist for a few years and finally found this basket case Honda CB550 for $300. I pounced on it and it turned out that it was a 1 owner bike with 9700 miles and the guy was turning it into a cafe racer which I always liked. He started it so I figured I'd go with that. That was 2 years ago and I rebuilt and refinished the motor over the first year and then took a year off to do some large home projects. When I got back to it this past November, I started working on cleaning up the frame and the poor quality of the workmanship from the original owner made me start to have misgivings. The frame loop that he did was pretty nasty and I really want to build a high quality old bike so I decided to cut it off and start over. The other misgiving I've had is that I'm 67 and cafe racer riding position concerned me. I started looking at options and found some cool tracker style seats and since that was my original idea, decided to go for it.

« Last Edit: January 31, 2024, 07:13:56 PM by chesterburnet111 »
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Offline grcamna2

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Re: My $300 77 CB550F Project
« Reply #1 on: January 31, 2024, 03:54:50 PM »
Welcome to the forum.
Do you still have enough original length rear seat rails to use the rear most fender mounts ?
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 chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #2 on: January 31, 2024, 06:12:45 PM »
Welcome to the forum.
Do you still have enough original length rear seat rails to use the rear most fender mounts ?
Actually I do. The previous owner cut the rear section and fabricated a rear hoop that welded to the outside of the frame and save the original frame section. When I cut off his piece and cleaned it up, the old piece matches up perfectly and needs to be welded back on which is my plan as it supports the new seat section.
« Last Edit: January 31, 2024, 06:39:04 PM by chesterburnet111 »
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Offline grcamna2

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Re: My $300 77 CB550F Project
« Reply #3 on: January 31, 2024, 06:28:49 PM »
Nice  8)  ;)
I'm glad the other previous owner saved the parts.
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: My $300 77 CB550F Project
« Reply #4 on: January 31, 2024, 07:33:53 PM »
Following progress.....

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #5 on: January 31, 2024, 09:48:19 PM »
My original plan was to do this semi cost effective using as many original parts. That was going pretty well until I started thinking about carburetors and Googled them and discovered Murray's Carburetors. Besides getting rave reviews, I thought they look incredibly cool so I bought them. Then, I Googled electronic ignitions and discovered Motogadget. Game Over. I was done in by Google. I geek out over modern technology, especially on motorcycles. I love all the technology on my MT10 and all of a sudden I had a new vision for this. I decided I wanted to use all of the Motogadget stuff I could and thought it would be cool to incorporate as much current technology without and try to make it look like an old school build. I kind of lost my mind. So far I've spent over 7K on parts. I rebuilt the top end of the motor and new electronic ignition. The previous owner painted the motor red for some reason. Removing factory paint and the red paint was brutal. Even after using aircraft paint stripper, I spent the entire summer wire brushing it off with a Dremel and then sanding. I also taught myself how to refinish and polish aluminum. It's a lot of work but I've noticed that a lot of people avoid the grunt work and paint everything black. Frankly, I'm sick of black motorcycles and everything painted black. They're all starting to look the same.

« Last Edit: February 02, 2024, 04:43:22 PM by chesterburnet111 »
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Offline grcamna2

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Re: My $300 77 CB550F Project
« Reply #6 on: January 31, 2024, 10:11:56 PM »
Will you paint the engine a different color now ?
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 chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #7 on: January 31, 2024, 10:36:31 PM »
Will you paint the engine a different color now ?
It is already painted Duplicolor silver and black engine paint.
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Offline denward17

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Re: My $300 77 CB550F Project
« Reply #8 on: February 01, 2024, 04:47:40 AM »
Looks great!

Offline Stev-o

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Re: My $300 77 CB550F Project
« Reply #9 on: February 01, 2024, 08:04:53 AM »
$7K?!!!  Wow, the cheapest bikes are the most expensive!

I think you made a good choice not to go the cafe route, that riding position is not comfortable for more that 30 min.

Cal is our resident Motogadget, expert when/if you have questions.  Good luck!

PS. Love polished aluminum, nice job.
'74 "Big Bang" Honda 750K [836].....'76 Honda 550F.....K3 Park Racer!......and a Bomber!............plus plus plus.........

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #10 on: February 01, 2024, 10:36:12 AM »
I've been checking out the Motogadget threads on here for a while. My biggest fear has been that CalJ (is it Cal?) would retire from the forum before I get to wiring this bike up. I think their stuff is beyond cool.

I bought the Motogaget M-Unit Blue, Motoscope Pro, blinkers, keyless lock and handle bar buttons last year.  Interestingly, they seem to sell out as quickly as distributors get them in stock so I decided to try and buy directly from Germany. To my surprise, they were available for immediate delivery and, due to the exchange rate, everything was about 1/3 cheaper even including DHL delivery.

Additionally I bought an electronic ignition from Charlie's Place and new higher output coils from Dynatek coils.
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #11 on: February 01, 2024, 11:11:29 AM »
Motoscope Pro needs the breakout box, I think?

Yes. I got one. Your reputation proceeds you and I was aware how helpful and well respected you are on this site. I figured I'd learn as much as I can before I started bombing you with questions. I'm not a beginner with electrical but I got a ways to go. When I started looking at the OEM wiring, I realized that it could turn into a major pain in the ass putting it back together and diagnosing issues on a 45 year old motorcycle. When I saw the M-Unit, it just clicked in my head that ultimately it was simpler, more reliable and way cooler. I'm also guessing that between the old wiring harness, battery, lights, that it drops about 20 lbs off the bike.

I see that there are a lot of people that are critical of the Motogadget & Murray's Carburetors that have no actual experience with them. I'm 67 and still working full time in a technology driven industry and I see that there are a lot of people that, as they get older are hyper resistant to new things and often are very vocal about it. I'm not one of them and I enjoy talking to other like minded people.

I have to say that I am amazed at the  amount of responses and conversation here. Way cool. I don't know a lot of people that are into this stuff.
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #12 on: February 01, 2024, 12:29:57 PM »
Motoscope Pro needs the breakout box, I think?

Peas in a pod.

For me, if I am going to invest time (the most precious commodity) into renovating/rebuilding something, then I am going to do so to the best level I can. That does not infer that “original” is inferior, but innovation occurs with time and these bikes are nearer to 50 years old than 5.

And I enjoy building bikes, cars, trucks, etc. But I much prefer RIDING bikes than maintaining them. So anything I can do to improve its reliability or upgrade its performance (suspension, braking, lighting…) I’m doing. To hell with Concours restos; they’re not my cup of Joe. I appreciate them, but I ride my garage art.
I completely agree. I appreciate the Concours restorations and am amazed at some of them but it's not what I'm looking to do. Honestly, I hate seeing truly rare cars and motorcycles get hacked up but a 77 CB550 is not rare. Garage art is a good way of putting it and I want to ride it.
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Offline grcamna2

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Re: My $300 77 CB550F Project
« Reply #13 on: February 01, 2024, 05:00:40 PM »
Motoscope Pro needs the breakout box, I think?

Yes. I got one. Your reputation proceeds you and I was aware how helpful and well respected you are on this site. I figured I'd learn as much as I can before I started bombing you with questions. I'm not a beginner with electrical but I got a ways to go. When I started looking at the OEM wiring, I realized that it could turn into a major pain in the ass putting it back together and diagnosing issues on a 45 year old motorcycle. When I saw the M-Unit, it just clicked in my head that ultimately it was simpler, more reliable and way cooler. I'm also guessing that between the old wiring harness, battery, lights, that it drops about 20 lbs off the bike.

I see that there are a lot of people that are critical of the Motogadget & Murray's Carburetors that have no actual experience with them. I'm 67 and still working full time in a technology driven industry and I see that there are a lot of people that, as they get older are hyper resistant to new things and often are very vocal about it. I'm not one of them and I enjoy talking to other like minded people.

I have to say that I am amazed at the  amount of responses and conversation here. Way cool. I don't know a lot of people that are into this stuff.
Peas in a pod.

For me, if I am going to invest time (the most precious commodity) into renovating/rebuilding something, then I am going to do so to the best level I can. That does not infer that “original” is inferior, but innovation occurs with time and these bikes are nearer to 50 years old than 5.

And I enjoy building bikes, cars, trucks, etc. But I much prefer RIDING bikes than maintaining them. So anything I can do to improve its reliability or upgrade its performance (suspension, braking, lighting…) I’m doing. To hell with Concours restos; they’re not my cup of Joe. I appreciate them, but I ride my garage art.

I appreciate what you're saying  ;)
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 chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #14 on: February 02, 2024, 06:50:09 AM »
I received my seat this week and last night I put it on top of the frame to eyeball it up. It's made out of plastic so I'll have to figure out a way to mount it. I want it to have a way to put it on and off quickly and easily so I can access storage and electronics. I figured that there are some big brained people that have puzzled over this and come up with some innovative solutions. I've never been shy about adopting a good plan or idea. I posted a picture of the seat earlier in this thread. 
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Offline MauiK3

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Re: My $300 77 CB550F Project
« Reply #15 on: February 02, 2024, 07:00:45 AM »
Quite a project!!
1973 CB 750 K3
10/72 build Z1 Kawasaki


Offline Floshenbarnical

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Re: My $300 77 CB550F Project
« Reply #17 on: February 02, 2024, 07:15:48 AM »
Motoscope Pro needs the breakout box, I think?

Yes. I got one. Your reputation proceeds you and I was aware how helpful and well respected you are on this site. I figured I'd learn as much as I can before I started bombing you with questions. I'm not a beginner with electrical but I got a ways to go. When I started looking at the OEM wiring, I realized that it could turn into a major pain in the ass putting it back together and diagnosing issues on a 45 year old motorcycle. When I saw the M-Unit, it just clicked in my head that ultimately it was simpler, more reliable and way cooler. I'm also guessing that between the old wiring harness, battery, lights, that it drops about 20 lbs off the bike.

I see that there are a lot of people that are critical of the Motogadget & Murray's Carburetors that have no actual experience with them. I'm 67 and still working full time in a technology driven industry and I see that there are a lot of people that, as they get older are hyper resistant to new things and often are very vocal about it. I'm not one of them and I enjoy talking to other like minded people.

I have to say that I am amazed at the  amount of responses and conversation here. Way cool. I don't know a lot of people that are into this stuff.

I think I'm biting the bullet and going m.unit this year. It just makes the most sense. I'll be buying it in March when I actually have the money
"All things change in a dynamic environment. Your effort to remain what you are is what limits you."

'77 CB750 SS

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #18 on: February 02, 2024, 07:29:14 AM »


I think I'm biting the bullet and going m.unit this year. It just makes the most sense. I'll be buying it in March when I actually have the money
[/quote]

Check out buying it direct from Motogadget in Germany. The exchange rate is still quite favorable and you can save a good chunk of cash.
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Offline Floshenbarnical

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Re: My $300 77 CB550F Project
« Reply #19 on: February 02, 2024, 11:33:56 AM »


I think I'm biting the bullet and going m.unit this year. It just makes the most sense. I'll be buying it in March when I actually have the money

Check out buying it direct from Motogadget in Germany. The exchange rate is still quite favorable and you can save a good chunk of cash.
[/quote]

Thanks for letting me know. I know Revival Cycle puts together and sells a big bundle of wires as an optional accessory with their m.unit, I might pick that up.
"All things change in a dynamic environment. Your effort to remain what you are is what limits you."

'77 CB750 SS

Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #20 on: February 02, 2024, 05:50:57 PM »
One of the things I really like about this forum is that there are so many quality builds. There's a lot of different directions that they go and I appreciate a lot of different styles even when they are not my style. I'm blown away by some people's fabrication skills. I also get it that some people just want a good reliable older motorcycle and don't care a lot about restoring them back to new condition or upgrading performance. Older Honda's always had good sound performance. That being said, and this rubs a lot of people the wrong way, but I detest builds that are only about the looks to the extent that they degrade performance and end up with almost unrideable or unsafe motorcycles. I've watched Orange County Choppers and rarely didn't think that their typical build was a death machine. I'd feel safer riding down I195 here in Massachusetts at 165 MPH in traffic on my MT10 then riding one of those bikes at 30 MPH and trying to make a turn. There seems to be a trend where cafe racer type builds (not here) are becoming totally art projects. I lived through some of the original cafe racer years and that was about trying get better performance out of their motorcycles. More and more often I see these things with 1" of suspension travel because it looks cool. This totally blows my mind and there are people giving out advice about suspension with no clue how dangerous it is. Quite often they will double down to try and discredit people that actually are giving good advice. I want a motorcycle that performs well and that I can ride. I put on 6,000 to 12,000 motorcycle miles a year.

I'm hoping that my Honda build is going to look killer but I also want to upgrade performance and reliability wherever I can. My motor is done and I think it'll have better performance than it was originally stock. With some help, I think my electronics will be very good. This CB550 seems to get a lot of praise as a good handling platform to begin with. I'm going to get the weight of this bike down substantially. The progression of making modern motorcycles lighter is amazing. There are parts on this Honda that weigh a ton. I've stripped off everything that I can. I bought aluminum rims and am changing out every single control, button and original electrical system component. I'll be interested to get this on a scale when it's done.

Now don't get offended if you disagree.....I'm tired of black motorcycles, cars and trucks. For me, it's been done to death. IMO, on motorcycle builds, blacking out parts is an easy way around doing the grunt work to refinish old parts. If someone really just wants a machine to ride and doesn't want to spend a lot of time refinishing, I get it. This build is going to be as black free as possible. The tires will definitely be black.

Every time I see an older motorcycle with the aluminum polished out I get a little weak in the knees and decided I wanted to do that. I did my homework as I didn't know much about how builders get the results. I call it grunt work. My original trade is carpentry so I know how the dull tedious time doing the grunt work gets you to the end where people ooo and ahhhh. My motor took from June to October to get it paint ready. I wore out 2 dremels until I bought a 3rd high end one. In the process, I learned how to polish out aluminum parts. It's pretty simple, sand, sand, sand and then sand some more. Then it's polish, polish and polish again. Lots of hours. The outer cases came out pretty good. I've got a ton of hours in the frame but that gets powder coated so it's a little more forgiving. Currently I've spent the previous 2 weekends, both days working on the rear hub. Aluminum parts take a beating and my 550 only has 9700 miles on it. I figure I might finish it tomorrow if I work all day on polishing. That's strictly the hub, not the plate with the brake assembly. What else are you going to do in mid winter in Massachusetts when you motorcycle obsessed? I think it's gonna look pretty cool with new aluminum rims and new spokes.
Here's a few pictures of my progress.


« Last Edit: February 02, 2024, 06:32:21 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #22 on: February 02, 2024, 06:53:56 PM »
I've been at this build for 2 years already but having just joined this site, I'm trying to catch up.

I needed to do some more fit out work to use my garage as a shop. I had to run a new heavy duty electric circuit out there. I bought a huge tool box and a laptop so I didn't have to run in the house to look up stuff online and play music too. With 67 year old eyes, I need good lighting and remembered seeing loading dock lights which were bright as the sun. I found a brand new one on Ebay for $85. Works like a charm.

 
« Last Edit: February 02, 2024, 06:56:12 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #23 on: February 02, 2024, 08:19:19 PM »
I rode motocross bikes until I was almost 40. Never owned a street bike. Mostly because although I ridden street bikes, I didn't feel the same excitement as off road. I didn't ride again until I was 59. My GF asked me to go with her son to look at motorcycles because she knew I used to be into them. When she saw me geeking out over them at the dealers, she decided to buy me a Ducati Scrambler as a Christmas present. It took about 3 months and my motorcycle obsession was back. I'm on my 4th bike since 2016 plus this Honda build. I bought a 2017 Yamaha FJ09 and decided to do aftermarket suspension. Honestly, I didn't think I rode well enough to notice the difference but still dropped about $2500 on K-tech shock and cartridges. What I found out was that great suspension makes a huge difference. I traded the 09 for a new 19 MT10 and immediately ordered a K-Tech rear shock. Covid hit and I decided I was going to learn how to do forks and set up suspensions. I ordered a set of Ohlins cartridges and proceeded to install them. I read everything I could and watched a million suspension setup videos. I've gotten pretty good at it.

When I started this build, I knew I wanted great brakes and wanted great suspension without putting forks from a newer motorcycle. I bought a 2nd rotor and a set of CB750 calipers from Ebay. It's actually pretty cheap to go to a dual rotor setup. I lucked out and got some very clean used parts.

During my suspension research, I found out that having springs that match riders weight is the single most important thing you need to do. Preload doesn't make springs compensate for heavy riders. Japanese motorcycle companies tend to have very light spring rates. There is a reason why Ohlins, K-Tech, Penske, Nitron all make around 10 different spring rates for their shocks & cartridges. I'm 6'1" and about 260 lbs so I bought a set of Hagon for about $400 from Bella Corse sprung for my weight. I didn't feel like I needed to spend $800 - $1000 on shocks for a 50 HP bike. I think they'll work well for me.

Forks are more complicated. I wanted to keep the stock look so this is my plan. I bought a set of 77 CB750 forks from Ebay. They're about an inch longer than the 550 fork. I also bought a brand new set of upper tubes as there was rust on both sets and even when you clean rust off, it's probably going to be back because you can paint them to protect them. I bought a set of springs (for my weight) from RaceTech. I also bought a set of cartridge emulators for RaceTech. You have to drill the damping rods but it's not big deal as I have a drill press. The last piece was a nice set of fork caps with preload adjusters. Although I still have to deal with the spindly 35 mm fork tubes, I think the rebuilt forks will work well when I put them together. I keep thinking that getting modern upside down forks would be hard to get to work. I want to stay close to the stock geometry because I feel like it's the easiest to work with. Probably going to need a steering damper. I'll see.
« Last Edit: February 02, 2024, 08:21:47 PM by chesterburnet111 »
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Offline chesterburnet111

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Re: My $300 77 CB550F Project
« Reply #24 on: February 04, 2024, 06:06:44 AM »
3 Saturdays and 2 Sundays to get this sanded and polished out. I understand why so many people just paint them black. I've seen that there are companies that you can send these parts to get polished. I'm curious how they do it efficiently enough to make money at it. I still have to do the brake plate but that's only 1 surface so I'm hoping to get that done today and start assembling the rear wheel. New aluminum rim, spokes, sprocket, bearings and brakes shoes were about $200. I bought one of the cheap Rising Sun aluminum wheels from 4into1. I've looked at it and it's a decent looking piece. The reviews have all been about the same....it does the job and hasn't failed. I'm curious if anyone has actual experience with them.
« Last Edit: February 04, 2024, 06:24:38 AM by chesterburnet111 »
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