Author Topic: Dad's 1978 Honda CB550k  (Read 23861 times)

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Offline joegeis

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Re: Dad's 1978 Honda CB550k
« Reply #375 on: July 20, 2025, 09:02:41 AM »
While Mark's got my cylinders, my simple fork oil leak has turned into a whole front end job. Since I had the front tire off, I decided to get the fork lowers powder coated to match the wheels. I forgot to remove the bearings, so they got cooked and needed to be replaced. I went with All Balls this time, since I noticed a little greasiness on my fork tubes previously. Maybe these are better. I lost a circlip, so went ahead and replaced both of those. I finally got my spare oil lock piece. As I was getting everything cleaned up and reassembled, I found myself with three of them... I don't know what happened. The original must have been in my parts box the whole time and I just missed it. Ugh.

I also put on superbike bars, new grips and bar end mirrors. I had previously bought the 4into1 SS braided front brake line kit and a aftermarket master cylinder because my original one was seized so badly I couldn't rebuild it. Well, in order to get everything to fit on the smaller bars, I loosened the banjo bolt to adjust the angle of the brake line, and when retightening it I snapped the bolt! It took barely any pressure. It wasn't even secured to the bars yet. I was holding it in one hand! Cheap junk! Anyways, I didn't feel like trying to drill out the bolt from the MC and I didn't like the brake lever feel anyways, so last night I purchased a Nissin 14mm modern MC on Dime City Cycles. I' fine with the more modern look. In fact, I think it will go with my bar end mirrors. It just goes to show that there are no small and simple jobs!

What I thought would be a couple hours putting the front back together turned into most of the day and an extra $200 in parts... Anyways, here are some photos. I'll be cleaning up and porting the head and intake manifold today and lapping the valves and replacing the valve seals later this week. I'm almost certain my oil pan is leaking (or maybe its just been running down from my base gasket). Either way, I'll probably drop the pan since the exhaust is already off, replace the gasket and add some liquid gasket. I purchased Hondabond from Common Motor Collective, but they sent me Permatex Motoseal Gasket Maker 29132. I'm assuming this is the same stuff? I've also got some Permatex #2 on order from Amazon.





Offline BenelliSEI

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Re: Dad's 1978 Honda CB550k
« Reply #376 on: July 20, 2025, 12:11:14 PM »
Joe…. looking good! With the head Brocken off that banjo bolt, it should come out easily. Jam anything in there (the right size easy out would be better) and it should turn almost freely?

Offline joegeis

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Re: Dad's 1978 Honda CB550k
« Reply #377 on: July 20, 2025, 01:45:29 PM »
Thanks Benelli! No dice on that banjo bolt though. It's not budging! I have not yet invested in an easy out kit, and honestly I'm kind of excited about my pending upgrade anyways.

I did some work with the head today. I got the valves apart and started taking a brass brush to the valves and the combustion chamber (not sure what its called - but the spherical area where the valve faces are that's all carbon-y). My brass brushes are really fine/soft and not doing much work on the carbon unfortunately. How clean should everything before going back together? Of course I'll lap the valves so everything seats nicely, but is it important to get the valve stem, surfaces and chamber spic and span? Anything else I can use besides my soft brass rotary brushes that might work better but not damage anything?

Also, I severely underestimated how difficult it is to clean off the old gaskets and make the mating surfaces nice. I was using PB Blaster and a razor, but realized I was still lightly scratching the aluminum. I've orders some CRG gasket solvent, plastic razor/scraper tool a carbide scraper and some maroon scotch bright.

Finally i inspected my intake manifold to see how bad they lined up, however I think it actually looks pretty good. I can feel a tiny bit of a lip on each one, but much better than some of the photos I've seen around here. I'm also planning to do some pocket porting above the intake valve. I got my copy of Hondaman's CB550 book and some carbide bits and will give it a go later this week.

Here are a few photos, and a link to the album with more.



Offline grcamna2

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Re: Dad's 1978 Honda CB550k
« Reply #378 on: July 20, 2025, 02:46:56 PM »
How do your valve guides feel Joe ?
75' CB400F/'bunch o' parts'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline joegeis

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Re: Dad's 1978 Honda CB550k
« Reply #379 on: July 20, 2025, 03:57:10 PM »
How do your valve guides feel Joe ?

fine I think. I didn't really pay attention when slipping the valve stems out. I'll give them an inspection with the flashlight. Valves all felt tight when removing. No wiggle or play and no damage as far as I could tell so far to the seats.

Offline HondaMan

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Re: Dad's 1978 Honda CB550k
« Reply #380 on: July 20, 2025, 04:58:57 PM »
That old carbon should come off the valves OK with a rotary wire brush. 50 years ago I held them by their stems with 2 wood blocks (think: paint mixer stick, broken in half) and cleaned them with a wire brush in my trusty Black & Decker variable-speed electric drill (still have it!), then relapped them in their seats.

The stubborn carbon in the chambers will yield to a Swiss Army penknife's curved blade, nearly a perfect curve match (I have about 6 of those).
Sorry about the master cylinder's bolt, but you are not the first to report that - and not just for the Hondas, either . :(

I think "4into1.com" is crypto for "parts that failed inspection, sold anyway"...
See SOHC4shop.com for info about the gadgets I make for these bikes.

The demons are repulsed when a man does good. Use that.
Blood is thicker than water, but motor oil is thicker yet...so, don't mess with my SOHC4, or I might have to hurt you.
Hondaman's creed: "Bikers are family. Treat them accordingly."

Link to Hondaman Ignition: http://forums.sohc4.net/index.php?topic=67543.0

Link to My CB750 Book: https://www.lulu.com/search?adult_audience_rating=00&page=1&pageSize=10&q=my+cb750+book
Link to My CB500/CB550 Book: https://www.lulu.com/search?sortBy=RELEVANCE&page=1&q=my+cb550+book&pageSize=10&adult_audience_rating=00
Link to website: https://sohc4shop.com/  (Note: no longer at www.SOHC4shop.com, moved off WWW. in 2024).

Offline joegeis

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Re: Dad's 1978 Honda CB550k
« Reply #381 on: July 20, 2025, 06:23:49 PM »
That old carbon should come off the valves OK with a rotary wire brush. 50 years ago I held them by their stems with 2 wood blocks (think: paint mixer stick, broken in half) and cleaned them with a wire brush in my trusty Black & Decker variable-speed electric drill (still have it!), then relapped them in their seats.

The stubborn carbon in the chambers will yield to a Swiss Army penknife's curved blade, nearly a perfect curve match (I have about 6 of those).
Sorry about the master cylinder's bolt, but you are not the first to report that - and not just for the Hondas, either . :(

I think "4into1.com" is crypto for "parts that failed inspection, sold anyway"...

so, safe to use some steel on the valves, as long as I don't go ham? Was the rotary wire brush you used brass or steel?

yeah, no more 4into1 parts for me!!

edit - I tackled the intake manifold with the dremel as practice before doing the porting. It was more forgiving than I expected and I got a good feel for it. I did both where it connects to the head as well as where the rubber boots connect. I used the cone shaped bit, a sanding flap wheel and a maroon scotchbrite sponge bit. Its a significant improvement! I'll do a modest bit of porting with my new dremel confidence, staying well clear of the valve guide later this week. My exhaust port  has so much carbon buildup, I'm not sure where to even begin. The head does not fit in my ultrasonic tank either, so I suppose I'll have to do a little work with a few brushed by hand and some PB Blaster. I do plan to wash the head in the sink with soap and water once I'm all done cleaning up the ports, chamber and gasket surfaces. I don't believe there is anything on the head that will rust, right?

I'll also go after the valves and chamber with a steel brush, knife and/or wire wheel. Oh yeah, and I've been chasing the threads on all the bolts and nuts, and soaking all the pieces in Evaporust and giving them a little WD40 misting. All my hardware should be good and refreshed for reassembly.

I forgot to ask this before, but does it matter if the valve assemblies go back where they came from? I labeled and bagged everything so it all goes back exactly where it came from, but wasn't sure if it mattered. I would like to throw all the valves in the ultrasonic cleaner, but they will get mixed up that way.

Before/after:

« Last Edit: July 20, 2025, 06:59:06 PM by joegeis »

Offline grcamna2

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Re: Dad's 1978 Honda CB550k
« Reply #382 on: July 20, 2025, 09:06:38 PM »
I always like putting the valves back where they came from  ;)
75' CB400F/'bunch o' parts'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline BenelliSEI

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Re: Dad's 1978 Honda CB550k
« Reply #383 on: July 21, 2025, 05:07:49 AM »
Easy way to keep valves and stuff organized….

+1 to “back where they came from”.
« Last Edit: July 21, 2025, 05:11:29 AM by BenelliSEI »

Offline BenelliSEI

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Re: Dad's 1978 Honda CB550k
« Reply #384 on: July 21, 2025, 05:10:53 AM »
My “valve cleaning” set up….. Scotch Brite and Varsol after a good scrape with a pen knife. Plastic tubing protects the valve stem and box cuts down on the spray. Wear an old shirt!

Offline grcamna2

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Re: Dad's 1978 Honda CB550k
« Reply #385 on: July 21, 2025, 09:56:39 AM »
My “valve cleaning” set up….. Scotch Brite and Varsol after a good scrape with a pen knife. Plastic tubing protects the valve stem and box cuts down on the spray. Wear an old shirt!

Plastic tubing,then you install the valve in the drill press ?
75' CB400F/'bunch o' parts'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline BenelliSEI

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Re: Dad's 1978 Honda CB550k
« Reply #386 on: July 21, 2025, 11:48:41 AM »
My “valve cleaning” set up….. Scotch Brite and Varsol after a good scrape with a pen knife. Plastic tubing protects the valve stem and box cuts down on the spray. Wear an old shirt!

Plastic tubing,then you install the valve in the drill press ?

Yes.. clamp tight without risking damage if it spins.

Offline grcamna2

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Re: Dad's 1978 Honda CB550k
« Reply #387 on: July 21, 2025, 01:18:23 PM »
My “valve cleaning” set up….. Scotch Brite and Varsol after a good scrape with a pen knife. Plastic tubing protects the valve stem and box cuts down on the spray. Wear an old shirt!

Plastic tubing,then you install the valve in the drill press ?

Yes.. clamp tight without risking damage if it spins.

I want to have a shop(I'm in an upstairs apt.)w/ a drill press,hopefully someday soon.
I imagine you can spot whether a valve is bent or not,using the drill press.
75' CB400F/'bunch o' parts'
  I love the small ones too !
Do your BEST...nobody can take that away from you.