Author Topic: 75' CB550K Custom Build (Read 3134 times)

LMAERO_396 · « **on:** April 26, 2007, 07:32:13 PM »

So I just recently started a project to make a custom CB550K and have gotten the parts bike completely disassembled and sorting through parts now. The engine is next and soon I will pick up the running bike. I plan to start from the ground up with the current empty frame and build a "modernized" verson of the CB550K. I just have a couple of inquiries.

Anyone used other types of forks from different bikes on this model?

Anyone tried what I'm doing in regards to adding modern brake system, electrical systems?

Parts Bike before tear down.

more photos soon...

cafe75-550 · « **Reply #1 on:** April 26, 2007, 07:48:43 PM »

Well for starters thats already not a 550 front end, looks like it might be a '78 CB750F front end, maybe later ('80 or '81 DOHC 750) depending on the fork spacing. And I don't think the front rim is original to either of those bikes. So, it already has a more modern front end and brakes...

LMAERO_396 · « **Reply #2 on:** April 27, 2007, 08:20:11 AM »

really? I haven't had a chance to go through what I have and match up the parts. I knew the rims weren't as they say Kawasaki on them

FunJimmy · « **Reply #3 on:** April 27, 2007, 11:29:23 AM »

I'm currently grafting a 2000 Yamaha R6 front end to my CB550 and it may be easier than first thought. The Yamaha steer tube is the same diameter for the lower bearing as the CB550, but the upper steer tube diameter is larger and overall length a little longer. I’m going to use the same taper roller bearings on the top and bottom, but the top bearing will be installed in the head tube using a bearing cup just like a bicycle headset. That will allow me to use the Yamaha triples with alloy steer tube without having to cut the length down.

Interestingly the 1999-2001 R6 triples have almost the exact same offset as the CB550 triples. This should keep the factory geometry as close to the same as possible.

While you are at the lathe making up the upper bearing cup, machine two bearing carrier/disc spacers to sandwich the front hub. These will be the diameter of the CB front hub/disc mating surface and as thick as required to mount 1998 Honda CBR600 F3 rotors.

Calipers are the only thing I’m still working out. Yamaha R6 calipers are too wide and hit the spokes of the CB wheel. I’m looking at using other calipers or machining the mounting ears of the R6 calipers a little, combined with possibly milling a little off the inside of the caliper in efforts to clear the spokes. Must be careful not to breach the piston bores when milling the backs of the calipers though.

LMAERO_396 · « **Reply #4 on:** April 27, 2007, 01:08:00 PM »

That sounds interesting, I'm thinking of something similar and maybe replace the controls with something modern.

FunJimmy · « **Reply #5 on:** April 27, 2007, 01:58:32 PM »

Controls are the easy part.

Honda RC51 or CBR1000R throttle assembly will fit with your stock cables.
RC51 starter switch is a perfect fit too.
Buell front master cylinders are cheap on ebay, have mirror mounts and can be fit with a Kawasaki adjustable lever.
For the clutch lever, I went to my local Kawasaki shop and asked the service manager what they had in the spares box. He sold me a slightly used clutch lever with adjustable reach lever and a mirror mount for $30.00.
I then used a universal signal switch unit from (http://www.fourstrokesonly.com/Switches.html) and it all works and looks great. The switch comes with bullet connectors that plug right into the stock electricals too.

Cheers
Jimmy

shields102 · « **Reply #6 on:** April 27, 2007, 02:03:43 PM »

I am no expert there ZZR, but I think you have a kawasaki front end there.

I too am putting together a modernized 550 from the frame up. Its been an adventure so far. Everything that seems like it should work or fit is always off for one reason or another. A modern cb frankenstein is harder then it seems. Good luck though! I will look forward to posts of your progress.

LMAERO_396 · « **Reply #7 on:** April 27, 2007, 02:25:38 PM »

Thanks for the info Jimmy, that is exactly what I wanted to know.

LMAERO_396 · « **Reply #8 on:** May 02, 2007, 05:16:41 AM »

So, R6 Forks with Triples. Seems this will be my first task. I plan on customizing my frame and add some vintage race type fairing or a Buell type, not sure yet. This looking to be a lot of fun.

LMAERO_396 · « **Reply #9 on:** May 02, 2007, 04:54:00 PM »

Parts bike completely tore down. Engine is in work, hope to have it done soon but taking my time as I want to learn the internals of this engine.

Sorting through all these parts will be good fun

FunJimmy · « **Reply #10 on:** May 02, 2007, 08:14:21 PM »

Wow! You've yanked it alright.

Good luck

Gordon · « **Reply #11 on:** May 02, 2007, 08:17:51 PM »

Do yourself a HUGE favor and put all those little parts, screws, nuts, bolts, etc, in various plastic baggies and label them as to where they belong on the bike. It makes reassembly so much less of a headache!

LMAERO_396 · « **Reply #12 on:** May 03, 2007, 07:20:12 PM »

Quote from: Gordon on May 02, 2007, 08:17:51 PM

Do yourself a HUGE favor and put all those little parts, screws, nuts, bolts, etc, in various plastic baggies and label them as to where they belong on the bike. It makes reassembly so much less of a headache!

I have a parts organizer for stuff like this. I sorted through the good stuff and cleaned them up. Most of this stuff is for anything that I might need to fix on the actual running bike I'm getting. I did figure out my forks & wheels are from a Kawasaki, just not sure what model?

.RJ · « **Reply #13 on:** May 03, 2007, 08:34:34 PM »

Quote from: Gordon on May 02, 2007, 08:17:51 PM

Do yourself a HUGE favor and put all those little parts, screws, nuts, bolts, etc, in various plastic baggies and label them as to where they belong on the bike.

Unless someone took it apart for you and you bought it as a pile of boxes and a frame.... *sigh*

Next time I am starting with a complete, assembled bike. At least this one only cost me $300.

Blaize · « **Reply #14 on:** May 03, 2007, 11:24:52 PM »

Wow, $300 gets you actuall boxes! my first one was a $100 cb550 and I got it in lousy milk crates. Yep, so all the small parts had long since fallen all the way thru. Mind you, once it was done, I knew how EVERYTHING went together.

Jinxracing · « **Reply #15 on:** May 04, 2007, 02:53:20 AM »

I'm feeling lucky all of a sudden...mine was free with engine disassembled in rotten cardboard boxes. However, the pieces were so rusted that I had no choice but to buy a complete engine. Let yours sit out in the yard for a couple of weeks and you can use the same excuse.

.RJ · « **Reply #16 on:** May 04, 2007, 05:31:17 AM »

Quote from: Blaize on May 03, 2007, 11:24:52 PM

Wow, $300 gets you actuall boxes!

Boxes and a big rubbermaid bin! I think that was the best part of the purchase

2 more months and it will be back on the road... hopefully!

LMAERO_396 · « **Reply #17 on:** May 04, 2007, 06:00:54 AM »

I should have mine on the road in 6 months or so. Not really in a hurry as I want to learn as much as I can from this project.

LMAERO_396 · « **Reply #18 on:** May 05, 2007, 07:53:00 AM »

Well, I should be getting the actual project bike this weekend. Guess I need to clear out an area for it

I do have some parts I'm having trouble finding info on, such as the Kawi stuff that was on it and I may have some extra parts to get rid of soon. I also need to find some more info on Engine block painting etc.

LMAERO_396 · « **Reply #19 on:** May 06, 2007, 12:48:44 PM »

Concept Drawing for some fairings. Has anyone tried making Ram Air intakes for the carbs?

FunJimmy · « **Reply #20 on:** May 06, 2007, 05:30:50 PM »

I guess my comment would be....If you want a Ninga why not just buy one?

LMAERO_396 · « **Reply #21 on:** May 06, 2007, 05:56:51 PM »

nah, already got one

I got some ideas from the Racer fairings I've seen on the 750s etc. I'm toying with the idea but after I got the other bike today I think I will do a straight restore or something in the Cafe style, just trying to be original.

LMAERO_396 · « **Reply #22 on:** May 07, 2007, 09:52:09 AM »

Here is where I got an idea from and may retro fit the 750 stuff to my 550.

http://www.airtech-streamlining.com/hondaz/CR7501969-77SINCAM.htm

LMAERO_396 · « **Reply #23 on:** May 08, 2007, 07:28:09 PM »

ok, so I've run into my first big hurdle. The bike I picked up did run with the use of the Kick Start, as the starter button seems to be gone. I'm running the wiring diagram now to trace the lack of power as I get no lights at all when the key is in the "Run" position but that could be the bulbs are all blown. I have a battery that I'm charging overnight just to be sure.

News:

Author Topic: 75' CB550K Custom Build (Read 3134 times)

shields102