Author Topic: 550 cafe off and running (almost) pics (Read 4873 times)

TheFox · « **on:** September 14, 2008, 03:17:28 PM »

Here goes nothing. I just picked up this 500/550 a couple of months ago and I'm just starting to get going on it. Thought I'd invite you guys to come along. The bike itself is a '72 CB500 but the previous owner swapped in a '76 550 motor a couple of years back. He also powder coated the frame and straightened out the wiring somewhat. I believe the forks are off of another year to.
Here's what I've done so far; removed the front fender and center stand (hardly ever rains in Orange County and the center stand looked like it could become a liability), installed some clubman bars and modified the original indicator cluster/bar clamps. That's pretty much it so far. I've ordered a carb rebuild kit and it should be in next week. Hope to have the bike road worthy within the month. I plan on it being my daily driver between OC and LA. So, without further ado, here it is.
As it was when I first got it

Replacing the smoked coils

Clubman bars installed

Modified bar brackets

Hastily lopped off the mufflers (oops)

And here are the SLR quality pictures

Hacked the exhaust and removed the center stand

I like this one

I do have some other plans which include either making a fiberglass/carbon fiber seat, or just breaking down and ordering one from Airtech. I do plan on updating some of the controls. Like the ignition/kill switch, and all of the other indicator and low/hi beam selectors. I'm getting some hand controls and master cylinder off of a GSX-R from a guy at work. I'm hoping to use modern superbike parts to help the stability and control of this old bike. I'm working on making a panel on top of the bar clamps that houses all of those switches and lights. Here's my first attempt at it. I'm thinking the spade might be a little cheesy and a tad too small for everything I need to put in it.

Here is one of the prototype rearsets I made at work the other day.

I also made a tail light and L.E.D. license light bracket for it. I just need to buy the brake light. I'll pull that nasty ass old fender as soon as I can relocate the tail light and plate.

Well, that's about it for now. I need to rebuild those damn carbs and maybe I can get it on the road soon. I'll try to keep this as updated as possible. Until then, enjoy. Comments and criticism welcome.

Fox

CBGhia · « **Reply #1 on:** September 15, 2008, 05:27:38 PM »

I like it!! One thing though. the front fender brace helps stabilize the front forks. your handling may be sloppier. It does look good though, build your own seat, you can do it!

TheFox · « **Reply #2 on:** September 15, 2008, 06:02:48 PM »

thanks, I've heard that about the fender. Not sure I believe it. My fender looked like it was made of pounded out beer cans. Hope I can get it going soon though.

CBGhia · « **Reply #3 on:** September 16, 2008, 11:21:27 AM »

its not the fender but the brace under it. it looks weak, but it is pretty strong. You can just leave the brace and decorate it to your liking, or buy a fork brace off of ebay.

TheFox · « **Reply #4 on:** September 16, 2008, 08:31:21 PM »

I might have to see about buying or making a fork brace at work if it's really that big of a concern. Or, maybe I'll modify some forks off of a newer Suzuki like that one guy on here did. I don't want to bastardize it too much.

Fox

troppo · « **Reply #5 on:** September 17, 2008, 02:56:27 AM »

You clearly know your way around metal working machinery, make a brace yourself...
Someone posted a cad image a while ago, try doing a search for "fork brace" or something similar..
Looking forward to seeing your work on the old girl.

DarkRider · « **Reply #6 on:** September 17, 2008, 05:50:33 AM »

http://forums.sohc4.net/index.php?topic=29197.0 heres the thread i think troppo was thinking of.

troppo · « **Reply #7 on:** September 17, 2008, 05:56:58 AM »

Thats the one, thanks Darkrider..
Near the top on page 6, theres no measurements but it gives you a good idea of what you need.

TheFox · « **Reply #8 on:** September 17, 2008, 09:37:02 AM »

Thanks for the link. That'll make it a lot easier. I don't mind making the parts but I hate engineering them. I'm picking up my carb rebuild kit today. Hopefully that's all that's wrong with the motor. I also got the dimensions of that dresda swingarm. If it works well, I might make some more and sell them. Same with the rearsets and a seat if I decide to make a mold. Maybe I'll do a poll or something, but would anyone be interrested in a boxed swingarm, rearsets, or a fiberglass seat if I put out some quality products? I'm giving some serious thought to producing some stuff like that. The rearsets would be all CNC, the swingarm would be TIG welded chromoly and the seat all hand laid. I know that was a lot but some input would be great. Thanks

Brad

TheFox · « **Reply #9 on:** September 19, 2008, 08:28:02 AM »

just got my carb rebuild kits in. Hopefully I'll be a me to ride it by next week some time. I made a mount for my camera to sit on the handlebars so maybe I'll make a little video of the first run.

scartail · « **Reply #10 on:** September 19, 2008, 06:16:30 PM »

I wonder how your exhaust sounds. Very loud?

TheFox · « **Reply #11 on:** September 20, 2008, 02:52:16 PM »

Loud as he'll. Hopefully it'll sound better when I get it all tuned up and running better.

TheFox · « **Reply #12 on:** September 21, 2008, 08:24:52 PM »

So, I got through most of the BS involved with rebuilding the carbs and I hope to get them back on the bike some time this week. After working on VWs for years, I've learned a few tricks about keeping all those little ass parts together and organized. Zip lock bags are cheap and help keep 4 identical carbs and their respective parts separate. You just have to make sure and label the damn bags, which I almost forgot to do. Another helpful thing to have would be a nice can of good-old carb dip. Unfortunately for me, I live in the great state of California, where you can't buy carb dip anymore due to environmental concerns. I guess they decided to leave all the illegal hazardous waste dumping to the major corporations, of which I won't mention any names. Anyway, now thats off my shoulders. Here is the progress on the carbs.

Oops, exceeded my bandwidth on Flickr. You'll just have to take my word on the carbs. More pictures soon.

Brad

TheFox · « **Reply #13 on:** October 11, 2008, 09:25:31 PM »

Back to the bike finally. I just payed my buddy Steve a visit today and dropped some cheddar on him. Got a new MAC 4-1 and some filter pods. It's amazing how much of a difference there is over having straight pipes and no filters. These bikes have some really sensitive carbs. Anyway, I'm working on a seat and wrapping up the wiring on the bike. I'm supposed to be getting some sport bike items (i.e. levers, rearsets, M/C) so I'll have to update those as I put them on. Here are some updated pictures of me rebuilding the carbs and some as of today when I got the exhaust on.

Rebuilding the carbs

BTW, don't buy those cheap ass filters I've got on there

Here's the new MAC exhaust (sorry for the #$%*ty pictures)

That's about it for now. I'll take some more pictures when there's some daylight.

moham · « **Reply #14 on:** October 12, 2008, 05:13:44 AM »

What did you do with the old mufflers?

TheFox · « **Reply #15 on:** October 12, 2008, 08:29:37 AM »

the garbage ate them. I still have the straight pipes if anyone wants them.

moham · « **Reply #16 on:** October 12, 2008, 09:20:37 AM »

So you chucked the headers or the mufflers?

TheFox · « **Reply #17 on:** October 12, 2008, 09:22:34 AM »

still have the headers

TheFox · « **Reply #18 on:** October 15, 2008, 12:27:55 PM »

It runs!!! It f**king runs. Finally. I've been blasting the hell out of this bike for the past week. I love it. It does need a serious tune up, but it runs pretty well despite all that. So, I figured this is good a time as any to start working on other things until I can get the little bugs worked out.
So, I started to work on my cafe seat. I worked out the cowl that will be covered in fiberglass and the pan with some really nice foam rubber padding I swiped from work.
I also picked up some parts from a buddy of mine at work. He was pretty into sport bikes for a while and had some old parts I bought off of him. Amongst those parts was a set of 6 piston calipers off of an '06 Yamaha R1. Believe me, if I could figure out a way to make these work on my stock spoke wheels, I'd be all over it. I am a fabricator and machinist by trade, and could probably pull it off, but I'm not sure I need that much braking power. Instead, I think I'll use some Tokico twin piston calipers off of a GSX-r 600. Still probably more than I need, but they'll look #$%*in and will work a whole lot better than the stock one.
Next comes some rear sets I got off of an '05 GSX-r 600. Pretty straight forward. I might even be able to modify the existing exhaust hangers/foot peg hangers to accept the rear sets. While I'm at it I might put a disc brake on the rear to.

That's all I've got for now. Here are the pictures.

The rough seat (before fiberglass and upholstery)