Author Topic: Papp's 1971 CB500 Rebuild. LOTS O PIX! Updated 5/08/09 (Read 36993 times)

papp101 · « **Reply #50 on:** March 01, 2009, 10:51:59 PM »

Well, I . . .

Sourced 2 original sets of piston rings off ebay, as the other two were in spec and looking great.

Installed them on the pistons with no problems.

Ground out the ports on the head from ebay to replace the rusted one that came on the bike. Polished the exhaust ports and matched up the intake tracks.

Lapped all the valves, and made a simple tool to install them as the rental one from OReilly didn't work for #$%* in my application

Mounted all the pistons on the wrist pins with retaining pins, and used hose clamps as ring retainers.

All back together! Looks like #$%* but will be sandblasted before putting back in the frame. If you know someone who sandblasts or would let me come over and use/cleanup his or her rig, that'd be greatly appreciated.

Next up, cleaning the frame and fixing the forks. Mounting the repaired stator, Cleaning the chain and wheel hubs, Buying a battery, swapping for clubman bars, fixing the front brake, mounting the rearsets and adjusting the linkage throwing the engine in, tuning the carbs, putting on the freshly painted tank/headlight assembly, mounting the brake light, putting on the exhaust, using the stock seat until I can fab up a fiberglass tail and I think. . . . then. . .

riding it.

papp101 · « **Reply #51 on:** March 01, 2009, 10:54:05 PM »

I don't have a good set of pics for this next run, but I'll show you some of the decent ones.

I've stripped down the frame and noticed the upper Triple is broken. A replacement is on the way from ebay.

The fork lowers looked like crap and the upper fork tubes are slightly pitted. For the lowers, I used stripper, sandpaper and the glories of the bench buffing wheel.

Cleaned up the front fender with a little WD40 and some 000 Steel Wool.

Decided to attack the front wheel with all the rust.

Used some heat on the 12 spokes that had some "rust" issues. Came right off!

Next up is getting the everything off the hub so I can strip and polish it, then polishing the leftover spokes, sanding and painting the rim black, and reassembling after the purchase of 12 replacement spokes and nipples. Who doesn't like replacement nipples?

I decided to outsource some of the work, so I mailed the entire caliper, tubing and master cylinder to my dad in Ohio. He'll probably repair replace anything I couldn't, and I can focus on the rest!

If you have any spokes you'd like to donate, I need about 14 spokes and nipples, 1/2 inner 1/2 outer for the front.

How the hell do you remove this stuff to get the front brake rotor off?

papp101 · « **Reply #52 on:** March 01, 2009, 11:53:48 PM »

What does everyone use for this tool?

Stuck here!Thanks.

oldhondarider · « **Reply #53 on:** March 02, 2009, 07:29:11 AM »

I believe I stick in the same place ... I tried to can get the bearing retainer and the rubber boot (stuck together) off with a flat headed screwdrive and light taps (bad idea- it's as soft as it gets) So...i bought a new setup but I couldn't find a tool a the local Honda dealer to put it back on....

DarkRider · « **Reply #54 on:** March 02, 2009, 08:08:45 AM »

As much as you probably gonna hate this answer...but you are probably better off replacing all the spokes in the wheel...using a mix of old and new spokes could make it a pain to true it later. Here is a source for new ones if you choose to replace all...

http://www.buchananspokes.net/

papp101 · « **Reply #55 on:** March 02, 2009, 01:11:28 PM »

I hear you on the spokes, that's why I'd like to go with someones good condition take offs- almost the same amount of time in the elements!

We'll see, life on the cheap.

OLDHONDA: I got mine out today by drilling the punch marks with an 1/8" drill about 1/8" down. Tapped right out - then I realized I didn't need it out, so I put it back in. DUH!

Benny · « **Reply #56 on:** March 02, 2009, 09:19:10 PM »

Papp Where in Minnesota? I am in the process of doing a 76 750, good to know there are northerners in the forum

papp101 · « **Reply #57 on:** March 02, 2009, 09:50:46 PM »

Uptown, You? Always good to meet up with another cafe builder!

***UPDATE***

Took off the rear tire (why did I buy such short tire irons. . . ow.) busted the rust off the inside with a wire wheel. De-Laced the rear rim and hit the spokes with the wire wheel as well.

I plan on doing the rim satin black, and the spokes maybe a bright silver rattlecan then cleared? I just need to pick somethign and get over it.

The brake hub got polished. Poorly as I haven't nailed down my sanding/buffing process yet. I'm sure it'll be fine.

Where is everyone getting the best price on avons?

More to come!

masonryman · « **Reply #58 on:** March 03, 2009, 02:56:48 AM »

I just skimmed through for thr first time, if you need a carb bowl I have some extra.

Mark

winnipeg550guy · « **Reply #59 on:** March 03, 2009, 06:59:12 AM »

Quote from: papp101 on March 01, 2009, 11:53:48 PM

What does everyone use for this tool?

Stuck here!Thanks.

Lots of ideas on this one, found a couple links here. My super cheap spanner took 5 mins. to build, no picks but all I did was took a small section of steel rod bent it into a rough U shape and clamped a pair of vise grips to the bottom of the U, Viola ! just remember the reverse threading.

http://forums.sohc4.net/index.php?topic=10550.0

http://forums.sohc4.net/index.php?topic=40052.0

fuzzybutt · « **Reply #60 on:** March 03, 2009, 07:07:04 AM »

DO NOT bead blast the motor while it's assembled! no matter how good you mask it those little bits will get inside the motor. and try taking a motor apart that has been blasted, those same little bits of sand, or glass beads, that get inside your motor will also get into threads and when you try to disassemble threads will get all bunged up as well. dont ask me how i found this out.

Benny · « **Reply #61 on:** March 03, 2009, 08:23:15 PM »

I am in Champlin, if you need any motorwork done, machining etc.. there is a guy in Anoka by the name of Bill Bune that does really good work. I just had him do my head for my 750 and it turned out awsome. i am looking for some good metric swap meets around town, but have not been able to find any. have you heard of any?

oldhondarider · « **Reply #62 on:** March 04, 2009, 07:33:33 AM »

Quote from: winnipeg550guy on March 03, 2009, 06:59:12 AM

Quote from: papp101 on March 01, 2009, 11:53:48 PM
What does everyone use for this tool?

Stuck here!Thanks.

Lots of ideas on this one, found a couple links here. My super cheap spanner took 5 mins. to build, no picks but all I did was took a small section of steel rod bent it into a rough U shape and clamped a pair of vise grips to the bottom of the U, Viola ! just remember the reverse threading.

http://forums.sohc4.net/index.php?topic=10550.0

http://forums.sohc4.net/index.php?topic=40052.0

SWEEEEET... thanks!

papp101 · « **Reply #63 on:** March 06, 2009, 12:11:59 PM »

Time for an update!

I ended up just drilling out the punch marks, and the retainer came off. Then I realized I didn't need to take it off. Whoops.

I'll let you browse through the rest of the pics as I need to go powerwash my frame. Yuck! Disassembled the front and rear hubs as well.

papp101 · « **Reply #64 on:** March 06, 2009, 12:14:17 PM »

Then I took the side cases off, and multi-tasked between stripping those and prepping/priming my rims.

Used a dremel with a stone wheel to gently buff down the pitting spots, then hit the whole thing with a scouring wheel and some acetone before painting. They look unbelievably smooth! Thought the grinding marks would show through, but no worries there!

papp101 · « **Reply #65 on:** March 06, 2009, 12:19:32 PM »

Got the polishing wheel going and had some issues:

I think my wheels need cleaning as they are leaving swirl marks, and I was using green compound (for stainless) as opposed to brown then white.

Also, I was using only "cutting strokes" which go against the wheel. I need to cut it with each, then move with the wheel for "buffing" or "finishing" strokes.

Also got my Kenda Challenger 657's in! Whoo hoo!

Also ordered new spokes front and rear from Partsnmore for 29.99 a set. Screw painting the old ones.

I ordered stuff from Caswell - some black compound for the heavy pitting and a spiral sewn wheel.

From now on I'll use Black on the Hard wheel, Brown on the Spiral and White on the Loose wheel. Cut one way and buff the other on each. My parts are pretty pitted, butif there's no scratches I shouldn't have to use anything but the wheels. Maybe 600 grit, but I've been told if I go from 600 to Brown I shouldn't have to go all the way through the 800, 1000, 1500 which would be nice.

DarkRider · « **Reply #66 on:** March 06, 2009, 02:52:23 PM »

Looking great so far man!

papp101 · « **Reply #67 on:** March 07, 2009, 02:36:39 PM »

Thanks man,

Just scored a set of sidecover and headcover stainless allen bolts for 20.00 shipped from
http://www.allensfasteners.com

11.00 shipping was still cheaper than others, and I left the hex heads up top to save on cost as I am cheap and broke.

masonryman · « **Reply #68 on:** March 07, 2009, 02:46:16 PM »

you never responded about the carb bowls, I have some If you need one, or did you already replace it

papp101 · « **Reply #69 on:** March 07, 2009, 02:51:47 PM »

Hey, thanks for chiming in, and especially for the offer!

Turns out I took them home to my dad's machine shop and I' purchased a replacement tube for 4.00 on some ATV site. he drilled out the old and pressed in a new one to match - I can't even tell which one it is!

Also had a rusted out jet retainer, and we "fabbed" one from some hardened spring steel.

Thanks again for the offer man!

papp101 · « **Reply #70 on:** March 09, 2009, 09:41:32 PM »

While waiting for paintable weather here in Minnesota, I decided to touch on the carbs after my work with at my dad's shop in ohio.

New main jet retainer spring from spring steel.

A good shot of the carbs from the underside.

The repaired overflow tube! Can you guess which one?

MMM. . . . shiny polished side covers.

Dipping in 3 litres of coca cola! Hope it works. I left them racked together as I just don't feel like taking them apart.

Spray-stripping with tal-strip the carb lids. I'll be making some gaskets for these. I'm sure some home-made ones will be fine, anyone have a recommended gasket material?

Polished and happy! Love that dremel!

MMMMM if only I could clean this thing in the basement. I'll just have to ponyup for 2 cans of engine bright, hit it with a scouring pad then wipe it with prep before I'm ready to hit it with the high heat engine "semi-gloss" black. Or maybe flat. Not sure.

SteveD CB500F · « **Reply #71 on:** March 10, 2009, 03:52:42 AM »

Did you make the carb jet retaining spring?

If so, would you entertain requests from other members who have broken/lost them?

cdoggy81 · « **Reply #72 on:** March 10, 2009, 07:42:27 AM »

Looking good so far!!!
A tip for the cola trick for me was to keep it covered to keep the carbonation up as long as possible.

papp101 · « **Reply #73 on:** March 10, 2009, 09:19:20 AM »

Steve: I made it at my father's shop in ohio, but I could probably build a few with the cutoff wheels in my dremel. I would need to have my source send me the spring steel and also try it once at home before I guaranteed it. If you're thinking of putting my on the resource list, feel free! I'll do a post of making one as soon as i get the materials.

Cdoggy81: I wish I could cover it! Based on my experiences brewing beer, if I covered the trash can the CO2 would still deflate as there's too much area to pressurize. Thanks for the tip and I'll be sure to do it next time! (I'll probably split the carbs then and will be able to put them in smaller containers individually.)

SteveD CB500F · « **Reply #74 on:** March 10, 2009, 09:22:07 AM »

Great. Thanks.

If you write it up, I'll post it in the Carb FAQ and put a link in the "Where can I buy..." FAQ

Steve

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Author Topic: Papp's 1971 CB500 Rebuild. *LOTS O PIX!* Updated 5/08/09 (Read 36993 times)

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Author Topic: Papp's 1971 CB500 Rebuild. LOTS O PIX! Updated 5/08/09 (Read 36993 times)