Topic: 550 project update- SHE RUNS!

[ieism]

I haven't visited the forum for a while, too busy with work. But I hope to have some more time the next few months to work on my new caferacer project.
This is my second 550, my other one is pretty much stock.

So I bought this bike for parts to put on the other bike, but it turns out it's already half done. It seems in pretty good shape already, although I have no idea about the state of the engine as it was not a runner. The engine -has been taken apart and new gaskets and rings put in.
The only things I still have to do are:
-Paint- I think the tank is going to be white or a slight metallic white. And the fender.
-Frame: I have to remove some more stuff, and maybe powdercoat.
-Tires
-Rearsets and other controls - I think I'll fit Tarozzi rearsets, and a new brakelever/cylinder too.
-Brakelines and other cables- Steel for the double front disk, this is going to be expensive though.
-Drill the brakedisks
-Electronic ignition.
-Remove the battery box and fit a smaller battery somewhere else, I COULD REALLY USE SOME HELP WiTH THIS ONE!! As i'm not sure what will work and what not.
-Exhaust- I really want the stock 550 headers with a Supertrapp endcan, but this will probably be too expensive as I don't have headers in good shape...
-Wiring
Headlight and taillight.
Change the revcounter to a nicer one.
Pods and rejet.

If that all works, next year I'll have the engine ported and ad a streetcam. But I can't really afford that now.


IMAGES REMOVED, sorry can't find them anymore.....

I've never attempted a big rebuild like this, so I could use your help . I'll keep this tread updated...sort off.

Ivar

UPDATE:

Just need to finish it.....must....finish.....bike.......  

[kghost]

Looking really good so far...

Great to see ya back at it. 

[Hush]

Dang that's purty! and I don't even like cafe's.
Not a bad buy for a "parts bike" buddy, luckily you have a real Honda to ride while this one is in rebuild so you can take your time (and money allows) to get it just right.

[HondaMan]

Wow!
Whatcha doin' to the head?

[ieism]

  I just got the head back today. It's ported and gasflowed, but nothing radical. It's an 8 to 9 percent increased flow now.
It still has standard valves, money was tight. I paid 170 Euro for the porting and gasflowing. He also machines the flat surface a bit to make it flatter. And that price included beadblasting, one new valve and removing and reinstalling the valves and springs. I think it's a pretty good deal right?

[ieism]

I put the head back on today, and testfitted the 4 into 2 pipes> I'll get some pics tomorrow.

Here's a little list of some of the things I did to the bike so far, it was a little more than I anticipated/ It also cost about 6 times more than I planned 

Dual brakes wit SS brakelines. Caliper and inner rotor painted gold.
New Domino racetrottle, modified bicycle cables to fit them.
Brembo Master cylinder / brakelever.
Replaced Tach with custom gauge, I made that one myself and a chrome shell around the tach.
Replaced wiring. Rewired everything to fit under the seat.
Took engine apart and painted it with 2 pack silver and a spraygun. Looks good now.
Removes all the stuff I didn't want from the frame, i'm no longer scared of anglegrinders .
Painted frame glossblack. Spraygun also.
New sprockets and RK gold chain.
New wheelbearings and stearing needlebearings/
Fitted LED indicator light.
New battery. Small Oddesey battery under the tail.
New tank and seat from Benjie. Painted myself with spraygun.
Tarozzi Rearsets with custom mounting.
New tires.
Koni shocks polished up, with powdercoated springs.
New rings on the pistons barrels honed.
Had the head flowed and ported.
Iridium plugs, new coils and electronic ignition.

It's a lot of fun seeing your dreambike come together in your own garage, but I didn't think it would be this difficult. Nothing ever fits the first time, and finding parts is a lot of work too.
I still have a lot off stuff to do, but the result is better than I thought I could manage.

[jpswino]

Lookin' good.

[KB02]

Where did you get tat tank? Or is that the one that came with it?

[kghost]

And why is the Honda wing going the wrong direction? 

[mrbreeze]

And why is the Honda wing going the wrong direction? 

Yeah....that jumped out at me too Kghost!!!! NIce lookin' bike though for sure.

[ieism]

That tank came with the bike. I didn't end up using it though, it was a little too short and a bit too high for my tast.
I might repaint it and put it on my other 550 one day.

Why the wing is facing the other way is a mystery to me too.

Here's some more pics with the engine back together. The pipes are not bolted on yet, just for looks.

[Soos]

WHERE did you get those bars???

Did they come with the bike?


Looks sweet!


l8r

[ieism]

They came with the bike, they are pretty common on SOHC4's though. I see them quite often here.

[MCRider]

They came with the bike, they are pretty common on SOHC4's though. I see them quite often here.

I was going to ask the same thing. On your bar the handles cross the "U" part making a "T" joint. Most of the bars we see Stateside have the mitered joints. I like the T joint better, purely a looks/personal preference thing. I had one with the "T" joint many years ago and would like to have it again for old times sake.  I can't find them in US.

I asked the question of I think it was 750Andy and he said he got them from a friend in Europe, so there seems to be the European connection, as I see you are in Holland. I think it is a Tommaselli design, which would be Italian.

So if anyone knows of a US distributor of the Clubman bar with the "T" joint,...holler out.

[MCRider]

I've actually bought a pair of these: http://cgi.ebay.com/ebaymotors/Clubman-Cafe-Racer-Style-Handlebars-CB750-KZ1000-NEW_W0QQcmdZViewItemQQ_trksidZp3286Q2em20Q2el1116QQitemZ350092727962
but as you can see they squish the end of the "U" tube down before welding it to the control tubes. Probably fine, but Looks cheap. I like the looks of yours.

[MCRider]

Woo Hoo I FOUND THEM!  http://www.guzzino.com/tocohaba.html

[ieism]

Might be a European thing then. My partsguy has these in stock new. His site is in Dutch, but he speaks English so you can mail him (info@honda.nl). He will ship them, but it will be expensive.



His website is: www.honda4.nl

[MCRider]

[quote SNIP  Might be a European thing then. My partsguy has these in stock new. His site is in Dutch, but he speaks English so you can mail him (info@honda.nl). He will ship them, but it will be expensive.

SNIP

His website is: www.honda4.nl
[/quote]

Thanks for that. I'll check in with him. (Wish I'd paid more attention to my Dutch language class in High School    )  My source has these also, http://www.guzzino.com/tocoadba.html  but I like the looks of yours. Now to do some figuring.

[MCRider]

Might be a European thing then. My partsguy has these in stock new. His site is in Dutch, but he speaks English so you can mail him (info@honda.nl). He will ship them, but it will be expensive.

SNIP
His website is: www.honda4.nl

I sent him an email and got a "permanent error" this address no longer accepts mail.

Oh and by the way, sorry for hijacking your thread, your bike looks really cool and 170Euro? seems very fair for the headwork. Is that about $250-$300 US?

[ieism]

oops. I mistyped the address.

info@honda4.nl

[MCRider]

oops. I mistyped the address.

info@honda4.nl

Thanks, that worked and I got this back immediately making me think it was an automatic response, but I can't read it.:
LS.,

Dank voor je mail.

Omdat we net weer open zijn, na twee weken vakantie, kan het even duren voordat je antwoord krijgt op je mail.

We doen ons best om zo snel mogelijk alle mails duidelijk te beantwoorden.

Gr,

Marion en Rene van Maanen

[ieism]

That's an automatic response. In Dutch

It's said he was on holiday last week and the week before, so it could take him a while to respond to emails, as he has to catch up on the last two weeks.

I know he came back Friday, as I spoke to him Saturday, so you should have a reply within a day or two.

[MCRider]

That's an automatic response. In Dutch

It's said he was on holiday last week and the week before, so it could take him a while to respond to emails, as he has to catch up on the last two weeks.

I know he came back Friday, as I spoke to him Saturday, so you should have a reply within a day or two.

Its funny how the more we are different the more we are the same.  dank voor je mail is Thank you for the mail. twee wweken vakantie is two week vacation.  I think.

Thansk I'll wait for his response.

[MCRider]

That's an automatic response. In Dutch

It's said he was on holiday last week and the week before, so it could take him a while to respond to emails, as he has to catch up on the last two weeks.

I know he came back Friday, as I spoke to him Saturday, so you should have a reply within a day or two.

Its funny how the more we are different the more we are the same.  dank voor je mail is Thank you for the mail. twee wweken vakantie is two week vacation.  I think.

Thansk I'll wait for his response.

Rene confirmed they are Tommaselli brand, but he doesn't ship to US, understandable. I've bookmarked the CA distributor and that long search is now over. Now to finish current non-cafe project and get on to the cafe where I'll pick up the Toma.. Clubmans.

[ieism]

Small Update:

I installed the rearsets, and the linkages.
MAde a little box under the seat for all the electronics.
Made a batterybox under the seathump.
Made a bracket for the licenceplate.
Finished the petcock and filler cap.

The motor runs now (sort of), but I took of the cabs to be ultrasonic cleaned. I was waiting on new mainjets and pods anyway....

The only thing I'm still not sure about is what type of taillight to use. I had two round LED lights installed, but they looked too modern. I think I need something like those Model-A lights you see on Harleys, but they are hard to find in nice quality here.
Any ideas?