Topic: She's home.. '76 CB550F

[newbiecb550]

Well here we go...

Picked her up today and unfortunately she's in the shed for the time being due to the wife saying so. Rode her about 20 miles home in the cold, which would have been easy if I didn't forget my gloves! But gave me some time to get used to her. Once I threw her on the center stand, I went over it a bit more. I'm the third owner, unknown miles. Guy who sold it didn't ride much anymore. Bike runs pretty good, some flat spots but expected as he rebuilt the carbs years ago and never synced them on the bike. He's never adjusted the valves in the 5 years he's owned it and the fork seals are leaking. Tires are 20(!) years old so those will be gone. Runs rich and stinks of fuel but rather rich than lean. Odd slip on(?) muffler that will be replaced, hopefully that's an easy fix.

So the plan is to get to it a brat/cafe style eventually. I don't want to hack up the frame and while there are some non original parts like the speedo/tach (replaced by PO and reads 67k).

Up first, all the mechanics before the good looking parts.

-Adjust vales (curious how off they are)
-Cam chain tensioner adjustment
-Adjust clutch (engages at the very end, hate it)
-Replace fork seals/oil
-Install Dynatek electronic ignition
-Buy/install regulator/rectifier from Rick's
-Remove carbs and send off to Romax Cycles
-Adjust chain slack (wayyyy too loose)
-Conduct compression test
-Most likely will replace spark plugs (NGK D7EA)
-Replace brake fluid
-Buy digisync carb tool and sync
-Replace 20 year old tires!
-Replace pod filters with stock airbox

Long list! But that's just to get her up to road worthy. Then I'll start worrying about cosmetics. Attaching some photos, curious as I saw some black hoses hanging from each carb just venting to the atmosphere. Are these some sort of emissions thing where they vent back into the stock airbox? Will work on her Wednesday and hopefully have her inside eventually!

Ugh phone didn’t save some photos so only have a few.

[denward17]

Welcome to the forum and good luck with restoration.

Will be following.

[newday777]

Welcome to the forum newbiecb550
You didn't run it by the wife before buying it?? Rutroh....

What was the temperature and where are you?

[Mark1976]

   Great bike, you'll enjoy it. Find a decent pipe!

[newbiecb550]

Welcome to the forum newbiecb550
You didn't run it by the wife before buying it?? Rutroh....

What was the temperature and where are you?

Bit of a disagreement at the moment, will be worked out soon! about 50 and in the northeast.

[Alan F.]

Welcome to the forum newbiecb550
You didn't run it by the wife before buying it?? Rutroh....

What was the temperature and where are you?

Sounds like he's close enough to invite to Oxford, MA or Rochester, NH on May 18th

[HondaMan]

Tell her the bike will pay for itself in gas mileage saved.

...works for me...

[newbiecb550]

Got some parts in, gotta have the right tools for the job! JIS kit, trickle charger, correct size feeler gauges for valve job, test light and Dynatek electric ignition.

Also grabbed the battery to have it on a trickle charger. Removed the pods and will donate them via Facebook. Plan on removing the carbs Wednesday to get them shipped out. Thing runs so rich I reek of gas anytime I’m working on it.

[newbiecb550]

Got a few minutes today and removed the tank, got the carbs off and ready to be shipped. Also knocked out the cam tensioner adjustment. Tried loosening all the tappet covers but half were on so tight and my gear wrench decided to fail, garbage it went, that I didn’t want to further mess with it. Also looks like I damaged one of the throttle cable ends when removing the carbs. Didn’t realize there were two!

[denward17]

Where are you sending your carbs?

[newbiecb550]

Where are you sending your carbs?

Romax cycles. Can’t upload a photo of the broken throttle cable. Keeps taking me to start a new topic

[newday777]

Where are you sending your carbs?

Romax cycles. Can’t upload a photo of the broken throttle cable. Keeps taking me to start a new topic

Your photos are too large for the forum requirements.
I screenshot my pictures before posting, crop the excess. That makes my pictures small enough.
I'm in southern. Like Alan posted, we go to Riceorama and Jap Bike Mike's Swapmeets in Oxford MA.

[newbiecb550]

Okay thanks! Here’s a photo.

[newday777]

Okay thanks! Here’s a photo.

Can you push the end back on the cable sheath and crimp it?

[Stev-o]

Okay thanks! Here’s a photo.

Can you push the end back on the cable sheath and crimp it?

Hard to see but is the cable frayed?  May be time for a new set and yes, there are two - "pull and push".

The hoses on the float bowls direct overflowing fuel off a hot engine.

Be sure Romax does not use aftermarket carb kits, they cause tuning issues. 

[newbiecb550]

Okay thanks! Here’s a photo.

Can you push the end back on the cable sheath and crimp it?

Hard to see but is the cable frayed?  May be time for a new set and yes, there are two - "pull and push".

The hoses on the float bowls direct overflowing fuel off a hot engine.

Be sure Romax does not use aftermarket carb kits, they cause tuning issues.

I’ll check in a few days and actually take a photo. Got it. Didn’t know there was a pull and a push!

I asked Romax and this is what they replied with.

“ So It's a mix. I generally source all of my rebuild parts independently from Japan and oem like partzilla, but not every part is always available, so for some parts, they must to be sourced aftermarket because they're the only producers of those parts. But I only install parts I've tested and used myself. I need to be able to trust the parts I'm installing.
The service also comes with a full warranty, any issues get fixed at no charge and no wait.”

[newday777]

How far is Romax from you??

[newday777]

The gasket sets(#1) and the float valves(#2) are all you should need and are available from Honda for the carbs. The slide needles and jet emulsion tubes should be fine to clean and reuse along with the other brass jets.

https://www.southsoundhonda.com/--xpartsstream#/Honda_Powersports/CB550FA_(76)_SUPER_SPORT_550_FOUR%2c_JPN%2c_VIN%23_CB550F-2000003_TO_CB550F-2010866/CARBURETOR/b3284679-ab4c-427a-8b68-959c823bd603/ca5e2e1e-6ebb-46f2-bf9e-908b03011fed/y

Did you pop off the carb float bowls and get pictures??

[Stev-o]

The gasket sets(#1) and the float valves(#2) are all you should need and are available from Honda for the carbs.

That is not necessarily true, you would need to confirm the carbs have genuine Keihin brass parts first.
Who knows what has been done by a PO?

And as far as Romax's statement  "but not every part is always available, so for some parts, they must to be sourced aftermarket", that may be true but genuine parts can always be sourced from eBay and/or forums such as this one.  But shops only want to buy new parts as it's easier and less chance of buying a damaged part. 

Having genuine Keihin parts is imperative to getting a good carb rebuild that will insure a good running bike.   Trust me, I've been there...

[newbiecb550]

How far is Romax from you??

States away, I couldn't find any place online that was local to me and I wanted to use someone who specialized in carb rebuilds and didn't want to keep searching online. To answer your question in the other post, no I didn't pop off the carb float bowls. I just popped them off and shipped them out. When I was looking at the carbs, it seemed like a few semi stripped screws and even one of the bowls didn't seem tightened evenly with the rest. Since I have zero experience with carbs and not tons of time these days, I'd rather outsource stuff I don't feel comfortable to the experts.

[newbiecb550]

The gasket sets(#1) and the float valves(#2) are all you should need and are available from Honda for the carbs.

That is not necessarily true, you would need to confirm the carbs have genuine Keihin brass parts first.
Who knows what has been done by a PO?

And as far as Romax's statement  "but not every part is always available, so for some parts, they must to be sourced aftermarket", that may be true but genuine parts can always be sourced from eBay and/or forums such as this one.  But shops only want to buy new parts as it's easier and less chance of buying a damaged part. 

Having genuine Keihin parts is imperative to getting a good carb rebuild that will insure a good running bike.   Trust me, I've been there...

Yeah my guess is the latter, not wanting to take chances from some one off buyer. They seem pretty reputable and looked up a few random reviews and with the warranty, I feel confident it'll run pretty solid. I'm also picking up a carb sync tool to do once it's on the bike as I found a video online on how to do it and looks super simple.

[newbiecb550]

Alright a bit more tinkering. Got the stock air box in from eBay, looks like it’s missing some parts but I’m sure you guys will confirm. I’ve circled in photos from the assembly thread (what a huge help!!) what it didn’t include. Also came with these brackets with welded in screws. Do these look familiar to anyone? So far I’m missing the two tubular spacers, the oval shaped nut which secures the plenum to the case, the foam piece that goes on the bottom of the air box (but I do have the rectangular gasket), and missing the tool tray/air cleaner cover. Oh I’m also missing the piece that secures the air filter, small black thing circled as well. However, mine did come with this air inlet thing which I have a separate photo of. Did the seller pull this not off a CB550F?

The carbs got to the rebuild place today but wanted to test fit the air box since I’ve never messed with one. Fitting between the battery box and electronics was tight! Wasn’t sure if that’s because the PO told me he rewired the whole bike and a large wire loom hugs the frame.

Does the stock clutch cable route between the plenum stacks? That was the only way it didn’t rub. Also discovered one of the boots on the plenum is ripped, so that’ll need to be replaced.

Also took a good photo of the ripped “push” throttle cable. Pretty sure I need a new one.

I assume it was the PO who wrapped the side covers in this weird black material. Under them, the side covers had been spray painted black and you may be able to see some of the original blue. Shame. Either way I’ll run them without that ugly wrapping until I get the tank and covers painted. I’m thinking an OD green (black out the Honda emblem) with a black seat but that’s so far off I’m not really thinking much about it now.

[newbiecb550]

More photos. And of course, the 5 out of 8 tappet covers are not coming off but instead becoming even more rounded out. So that’ll be a fun project as most looked like they were already starting to round. Mystery intake photo and random bracket bolts attached.

[newbiecb550]

Photo of the push cable, ugly material removed from the side cover covers.

[newbiecb550]

Last few. One of the ripped plenum boot and a starting to get rounded tappet cover. 12 point or whatever 17mm socket is trash. Tried with some 17 ratchet wrench that also went trashy. Next up 6 pt 17mm socket and 5 new tappet covers.

For those and fork seals, partzilla??

[grcamna2]

Welcome to the forum;you'll receive lots of good help here.

[newbiecb550]

Crap! Just saw on the thread linked below it’s for a K model. Do the 1976 F and K models have different airbox styles?

http://forums.sohc4.net/index.php/topic,151576.0.html

[newbiecb550]

Did a bit of research including the parts list photo. Looks like I do have all the parts minus the oval bolt, a few spacers and the filter screen, which someone said on Facebook I could just use uni filter. Thanks to another thread I found, it looks like those brackets with a welded nut are what hold that air cleaner duct in place.

Going to buy tappet covers, want them in non-chrome. What do you all think of getting them from here? I saw them on Common Motor Collective and Dime City Cycles. I've been reading 4into1 sells junk. Unless someone has a better option...

https://carpyscaferacers.com/shop/shop-our-store/motorcycle-parts-accessories/honda-cb500-cb550-cb750-parts-upgrades/honda-cb-tappet-covers/?gQT=2

[Stev-o]

Crap! Just saw on the thread linked below it’s for a K model. Do the 1976 F and K models have different airbox styles?

I've had both bikes, there are minor differences especially with the top, the K had a place for tools, the F had tools in a different location.  Check the fiche for part numbers, then you will know which parts are the same [if the numbers match]

https://www.partzilla.com/catalog/honda/motorcycle/1976/cb550f-a-super-sport-550-four/air-cleaner

https://www.partzilla.com/catalog/honda/motorcycle/1976/cb550k-a-550-four/fuel-tank-air-cleaner

PS. Bookmark the fiche for your bike, it is very helpful for assembly and gathering info and part numbers for ordering.

[newbiecb550]

Crap! Just saw on the thread linked below it’s for a K model. Do the 1976 F and K models have different airbox styles?

I've had both bikes, there are minor differences especially with the top, the K had a place for tools, the F had tools in a different location.  Check the fiche for part numbers, then you will know which parts are the same [if the numbers match]

https://www.partzilla.com/catalog/honda/motorcycle/1976/cb550f-a-super-sport-550-four/air-cleaner

https://www.partzilla.com/catalog/honda/motorcycle/1976/cb550k-a-550-four/fuel-tank-air-cleaner

PS. Bookmark the fiche for your bike, it is very helpful for assembly and gathering info and part numbers for ordering.

Yup I finally figured that out last night which is a great reference like you said. That’s how I figured out that the duct was good and the tray wasn’t meant for my bike.

[Little_Phil]

Yes the airbox top is different and no tool tray on the F, Tools stored in rear of seat. The top air duct is mounted on those brackets with the welded on stud with a couple of elaborate wing nuts that are often missing, but any M6 wing nut will do. The tappet covers always seem to fit a 16.8mm spanner. So always use a six sided socket on them.

[newbiecb550]

Got a bit more work done this past week. Makes it harder as the shed the bikes stored in is not by me, so I also don't have all my tools. Anyways, so a lot of not so great things happened.

First, couldn't get off the last tappet cover on #1 intake side. Very stuck. Luckily my buddy had a neat socket I haven't seen before, forgot to snap a pick, that I tapped on and broke it loose.

Then proceeded to adjust all the valves, first time for me doing that. Pretty easy minus #3 cylinder exhaust was a pain for some reason. About 6 or 7 I couldn't get the feeler gauge through until I loosened it, can't imagine the last time they had been adjusted. Also got in new tappet covers from Common Motor but they were not like the photo on the website, too shiny for me as I wanted the stock flat look. So waiting to hear back and will likely buy someplace else.

Figured I'd change the spark plugs, think I forgot to snap a photo of all 4 laid out. Unfortunately on #4 cylinder, something must have happened and when it broke loose, it took part of the top threads with it. Whole plug is black so I’m thinking it was already damaged and shooting carbon out of the cylinder. Bike ran alright when I bought it. Did some research and bought a Time Sert kit to repair it. Just came in today and watched a few videos on how to, looks easy enough. Will tackle that soon. Did finish the rest of the plug change, had NGK D7ES before and threw new ones in. They were just black from running rich.

Carbs have been received and getting rebuilt now. Also ordered a push throttle cable as I jacked mine up as I had mentioned, hasn't shown up just yet. Got a Ricks regulator/rectifier but want to get the bike running again before I go crazy replacing parts.

Started trying to piece the stock airbox I bought together. Such a tight fit with just the brackets, I'm not sure how the plenum box fits in to it. In fact, it won't. So I'll need to spend more time with that. Also one of the boot thingys on the plenum is ripped and I don't see a P/N on the diagram. Sooo.... yeah. Carbs will most likely be back next week and I'm hoping to have the throttle cable and Time Sert installed by then. Hopefully I sort the airbox debacle out as well so I can start her up. Also tried taking photos of the chain slack. Not sure if the rear tire is suppose to be on the ground but its more than 3/4" of slack as you can see. Chain needs a good clean too.

[newbiecb550]

More…

[Stev-o]

That head may have already had a repair done to it.

As far as the black plugs, you need to confirm the carbs will be getting genuine Keihin jets in the proper size.

[newbiecb550]

I’ll confirm that, just waiting on the carbs to get shipped back. Got my Time Sert kit in so hopefully I can knock that out this week. Also received a new push throttle cable. May be a few inches longer, hopefully that’s not an issue. Will change the bars down the road. Also snapped a photo of all the plugs, 1 thru 4 respectively.

[newday777]

You want to look inside the ceramic to get your color reading

[newbiecb550]

Thanks, I posted #4 a few posts up which looks carbon fouled. I’ll take a better photo of them this week.