Topic: Complete idiot starts a CB550 Cafe build

[tjf]

And the complete idiot is me.  I just bought this bike for the sum of $500.


It belonged to a friend who bought it and wanted to make it his GF's bike, but then they broke up.  It ran fine until he put 750 carbs on it and now it wont start. 

My plan: turn it into this:


The problem:  I know nothing about bike assembly/repair. 

I can buy the tins from this site:http://www.benjiescaferacer.com.  I have a friend that will do the exhaust work and I can do paint.  I am a decent mechanic with cars and shifter karts, but have never done a bike.

Tell me everything I need to know about bike building/disassembly... specifically, tell me everything I need to know about a 1975 Honda CB550!!!  Is there anywhere I can get modern brakes for this thing?  What is my best option on an engine rebuild (if it needs it).  How the hell to I assemble triple trees and controls on a motorcycle?  Is there anything I really need to know before a complete teardown (any reverse threads, etc...)?

Im sure I will have more questions, but that gets me started :laugh:

Thanks 

[FunJimmy]

Wow. We'd be writing an essay to cover all that you want answered.

If you’re good with tools and have worked on cars and shifter carts, motorcycles will be just another fun project for you.

Search out the manuals on this site, download them for future reference, and prioritize your build goals.

Start reading all the 550 project threads on this site for inspiration and answers to your current questions and most of your future questions. When you’ve read through all the 550 builds, take a look at the 750 projects. You’ll find great information on suspension options, engine upgrades, seat building, tank accents, brakes and so much more.

There is no better source on CB info on the planet.

Keep a log and post lots of photos for future generations like you.

Cheers
FJ

[bzr]

Hey, you sound just like me. Get a repair manual first, I'm using the Clymer one and it has a great few pages where it outlines what needs to be removed from the bike if you're stripping it to the frame like I did. Otherwise, if it's in good shape then looks like you just need to take the tank and seat off...

[tjf]

Thanks for the advice.  I spent most of the night reading the 550 builds on here.

The bike is in good shape, but Im still gonna tear it down to powdercait the frame. 

What I would like to do:

1.  Teardown the bike
2.  grind off all unneccessary brackets and tabs
3.  Frame coated black
4.  Motor painted silver with black heads and black covers
5.  coat wheels black (or maybe new wheels since these look a little rusty)
6.  brake upgrade of some sort
5.  BCR dolphin tank and seat (either in flat black or flat silver)
6.  make it all work

[andy750]

Hopefully you are going to at least sell the seat and current tank and not destroy what looks like a good stock (hard to find) part 

Bike looks too good to rip apart for what you are suggesting but hey its your bike. 

cheers
Andy

[burmashave]

tgf, do check the FAQ's. As I recall, there are several entries related to things you plan to do. If you prioritize and work on a few tasks at a time, you can keep members posted in this thread or another one you start to track progress. Folks will jump in with help.

6.  make it all work

That's what keeps lots of us here. ;-)

Good luck to ya.

[tjf]

Brought the bike home and tore it down to bare frame yesterday.  Tear down was simple.  Everything comes down with the same 4 or 5 metric wrenches.  I now have a bare frame sitting in the garage ready for a battery relocation kit and powder coat.

My questions on the frame:

1) How do you fill the threads/passages in the frame for powder coat so that they dont get gummed up?

2)  Is it safe to just strip and powdercoat the swingarm, or do I need to take out the inner bearing?

The wheels

The wheels are pretty badly pitted/rusted/  Nothing is too deep, but it is gonna take some elbow grase to clean them up for paint.  Should I try to salvage them or is there a place to get some cheap OEM wheels powdercoated black?

The front end= the nights only SNAFU.

I have never worked on a bike before and the frontend was very foreign to me.  I ended up removing it as one piece by removing the three head bolts on top, taking off the top of the triple tree and dropping it out of the frame.  When I did so, ball bearings exploded and went everywhere.  Im gonna need help finding new bearings and reassembling the whole kit and kaboodle when the time comes. 

[FunJimmy]

Your powder coater has synthetic plugs for all the threaded holes in the frame.
You should completely remove all bushings and sleeves that don't require pressing out of the swingarm.
Powder coating is baked at a very high temp and you will need to remove the sleeves to grease them anyway.

As for all those exploding balls……don't worry.
You should replace with tapered roller bearings anyway.
The ball bearings are crap.
Try AllBalls Racing available from http://www.z1enterprises.com/

Cheers
FJ

[tjf]

I ordered the new Cafe tank and seat today.  They will take a little over a month to be made and shipped.



I cant powdercoat the frame until the tins come in so that I can mock them up and do a little cut/weld on the frame.  So Im on a holding pattern there.

The motor should go out for a rebuild tomorrow and will be back shortly.  When it comes back, I will paint it and get it ready to be bolted back in.

What I do have to work on right now are the wheels and the front end.

Anyone know where to get a rebuilt front end for a CB550?  My forks are in fairly poor shape and I imagine I can get a rebuilt set for what it would cost me to refurb these.

[digiacomo racing]

i ordered fork tubs from forks by frank.and all the other stuff seals, clips, ect i ordered at the Honda dealer. also look on eBay

[tjf]

Hopefully you are going to at least sell the seat and current tank and not destroy what looks like a good stock (hard to find) part 

Bike looks too good to rip apart for what you are suggesting but hey its your bike. 

cheers
Andy

The bike is nice from far, but far from nice.  The seat is in great shape and will be sold.  The tank is in decent shape.  It has a ding and the factory paint is faded.  The rest of the bike is not nearly as clean as the pictures indicate.  If you want either of these parts, let me know.

[tjf]

I havent updated in a while but things are moving along.  These pics are actually from teardown on day 1 a couple months ago, I just pulled them off my camera.







The frame is off to powdercoat and has a new Benjies rear subframe welded in.  The engine is being rebuilt.  I should start re-assembly in mid-August.

[canttuckmyshirt]

Nice project. Did you go with the fiberglass or steel BCR setup?

[burmashave]

Are you rebuilding the engine, or did you ship it off?

[tjf]

Nice project. Did you go with the fiberglass or steel BCR setup?

I went with a steel seat and a fiberglass tank.

[tjf]

Are you rebuilding the engine, or did you ship it off?

I am having the local vintage motorcycle shop do it.  I wouldnt have minding trying it, but I simply dont have the time to do the motor if I want to have the bike on the road this fall.

I misspoke earlier as it really isnt getting rebuilt, just freshened up.  The motor only had 9000 original miles.  I just wanted it cleaned up with all new rubber and gaskets since the bike has been sitting for most of its 20 year lifespan.

[burmashave]

The frame is off to powdercoat and has a new Benjies rear subframe welded in.  The engine is being rebuilt.  I should start re-assembly in mid-August.

I am having the local vintage motorcycle shop do it.  I wouldnt have minding trying it, but I simply dont have the time to do the motor if I want to have the bike on the road this fall.

The race is on. :-) I went through the same race two years ago.

[tjf]

The frame is off to powdercoat and has a new Benjies rear subframe welded in.  The engine is being rebuilt.  I should start re-assembly in mid-August.

I am having the local vintage motorcycle shop do it.  I wouldnt have minding trying it, but I simply dont have the time to do the motor if I want to have the bike on the road this fall.

The race is on. :-) I went through the same race two years ago.

heh... the race is over.  frame wins

[tjf]

Update 11/25/08:

I have been working slowly on the bike.  The engine is painted and back in the frame.   The triple trees are back on... and that is about how far I am.   

I went to put the swingarm and front forks on... and hit a snag.  There are small bushings and soft washers on the end of the swingarm (where it mounts in the frame).  These disentigrated... where can I get new small parts for the swingarm???

Also, I have decided to just clean up the stock wheels.  Is it ok to powdercoat stock wheels whole or do I need to de spoke them and powdercoat the hub, spokes and barrel seperately?

Finally, I need to put the hand controls back on the new clip ons.  I couldnt get the wires to pull off the old bars, so I just cu them leaving about an inch of wire coming off the controls.  What is the best way to clean up the hand controls to make them look nice again?  Is there any trick to wiring hand controls or can I just solder/heatshrink tube them?

[tjf]

CONSIDER HOW YOUR EXHAUST AND REARSETS WILL MOUNT BEFORE YOU GO CHOPPING OFF YOUR REAR PEG BRACKETS. I NOW HAVE TO FABRICATE A BRACKET FOR MY EXHAUST BECAUSE IT WAS DESIGNED TO USE THE RIGHT REAR PASSENGER BRACKET AND I REMOVED IT.

Well, the frame is already cut, welded, and powdercoated, so Im through that door already.

That said, I planned to mount the exhaust and the rearsets to the factory exhaust mounts, so I left them on.  On a 75 550, the exhaust mounts are kind "stylized" so it doesnt really detract from the look of the bike.

[tjf]

What is your reasoning for stock controls?

I havent found a better option... do you have one?

[moham]

I went to put the swingarm and front forks on... and hit a snag.  There are small bushings and soft washers on the end of the swingarm (where it mounts in the frame).  These disentigrated... where can I get new small parts for the swingarm???

Hondaman on here makes modified swingarm bushings, if I'm not mistaken. I haven't used them but I will when the time comes. I think if you search the site you will find a ton of info on his product. I would imagine they are reasonable in price as well.

[cadyjam]

I have a 75 Honda CB 550 same color and everything i was just wondering what your doing with the stock tank and side covers. I am looking to bring the bike back to original.

[tjf]

I have a 75 Honda CB 550 same color and everything i was just wondering what your doing with the stock tank and side covers. I am looking to bring the bike back to original.

I was going to sell them. 

The tank is in decent shape, it has original paint (green) which needs a good polishing, the original badges are rough and it has a couple dime sized dings in it from the clip ons.  It has the original petcock and cap.  I cant use the petcock on my BCR tank so it will come with the tank if sold.  I am unsure if I can use the filler cap, but if it wont work, it will be included as well. 

The side covers, however, are in rough shape.  They are cracked and held together by what appears to be hot glue from glue gun.  The badges on them are in rough shape as well. 

[cadyjam]

I see i just have one sidecover that is cracked and the tank is in good shape but it has some scuffs and scratches that i would like to take care of. Anyway your build is looking great it will be nice to see it finished.