Topic: 1977 CB550 K cafe racer build

[traveler]

When I ordered it, it stated NON O-Ring, nickel plated chain.

It's a Saphire Chain....made by Diamond Chain, NON O-ring.

~Joe

[shorterdanny]

Just came across you build mate,,totally awesome, gona look sweeeet wizzing down the street, as many have said you are putting many to shame with your work rate.

where were you in afgan? might have seen you about. back out in jan for me...Canny wait......NOT

Danny

[fastbroshi]

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=110502174585&crlp=1_263602_263622&ff4=263602_263622&viewitem=&guid=381f45821270a02653034ff3ffca0893&rvr_id=&ua=WXI6&itemid=110502174585

Is that the one?  I tried for the life of me to find a 100-link version and couldn't. 

[traveler]

yes...that's it.  All you have to do is remove the links not needed.  Just wrap the chain up, center punch and drill out the rivet where you want to remove the excess chain....EASY.

Been to both Iraq and Afghanistan, and have 12 deployments under my belt.  The last trip, I was at Bagram....and it was nice to be inside the wire this time!

Thanks for the positive replies...it keeps me motivated.

~Joe

[traveler]

Got some more work done on the bike today.

Started by lubing my new throttle and clutch cables I bought from Motion Pro.  I used a kit, which came with the alumninum tool....worked about as well as can be expected.

After that I went ahead and drilled out the center of the nut that holds the top tree and stem together.  This was for my vent tube on the gas tank





I then used a 4 foot section of #6 wire and finished up wiring in my battery and starter wiring



Next, I jacked up the bike again, and pulled the sprocket cover.  What a mess!  Took forever to get it cleaned up, as Ihave the dreaded shifter seal leak!





After I got it cleaned up....I also cleaned up the frame area around it....this took TIME!



After I got the cover cleaned up, I did a little drilling on it to give it kind of a distinctive look





A piece of black leather from some mechanix glvoes I had that had a hole in the fingers from my engine cleaning was used to make a cover for my electrics.  This is to keep it from grounding out on the alloy seat.



The holes in the rear drum are done!  I drilled them with a 1/4 inch bit and countersunk the holes with a 1/2 inch bit, then used sandpaper to blend it all in.



Here is another view of my overflow tube and tank emblems



And a side view of the bike.  Now it's time to pull the rear wheel later on



comments?

~Joe

[Zaipai]

That is so f'in sweet you sure have some great idea's going on there. I like the vent tube, good call, I was wondering what you were going to do with that.

.: Scott :.

[traveler]

Thanks, Scott.

~Joe

[Kemp]

Really nice job, can't wait to see it finished and running. What will you use for exhaust?

[traveler]

Exhaust?  Chrome 4 into 2

~Joe

[kennydean2000]

Looks great, bet your itching to thrash it around the roads.  Is that the rectifier hanging below the seat bump?  Have you got clearance there with a rider on it?

Also - I really like the way you cleaned up the electrics.  I'll probably try the small battery thing too.  Being able to look right "through" the bike is a nice effect - focuses attention on the mechanical - and you've made those look great.

Finally - have you got any ideas yet on what you'd remove from the frame now that you're at this point?  You mentioned a Phase II where you'd pull it apart and make those mods.  The PO of the one I bought started down the cafe route then lost interest.  My intent is to get it fired up (once I put it back together) then tear it down.

Keep up the great work and the photos.

[bwaller]

Looks good Joe, but I still think clearance for electrics and now the damper bracket on the fork is bare minimum. First time out take it easy until you're sure.

[Zaipai]

Well I am not sure, but from the looks of it, the clearance should not be an issue, he would have to hit a very hard bump, or a deep pot hole to compress the springs that much, and since that seat does not accommodate two riders it should clear ok.. I might not be so sure if he had used standard shocks and/or had a two seater on it.  Just my thoughts on it and as always I could be way off base.

.: Scott :.

[traveler]

I always take it easy....I just like to cruise.

I have checked the front forks for clearance...I'm fine.

Thanks for the comments.

~Joe

[traveler]

A little bit more work today.

Back up on the lift



Pulled the rear wheel, and polished up the spacers, axle and castle nut.  Also went ahead and cleaned up the starter cover.  Not too sure what I will do with that, as the chrome is VERY thin, and pitted.



Sanded out the brake plate, still needs to be polished up



Started on the rear hub....the amount of "goo" on this thing was unbelieveable!  I had to clean it 3-4 times with gas, a screwdriver and 2 rags to get her clean...the entire cush drive was "goo"....also started on the brake side, as you can see the edge of the hub is starting to get a shine....but, my fingers are sore, so I'm taking a break for a few days.







~Joe

[theofam]

Traveler, I feel your scrubbing pain (I've been sanding most of the weekend)!  Your ride is looking schweeet!  Money well spent on the tank and cowl - they really make the bike!

[traveler]

Thanks.

~Joe

[Ryan 550k]

Also went ahead and cleaned up the starter cover.  Not too sure what I will do with that, as the chrome is VERY thin, and pitted.

Isn't cleaned up enough?  IMHO, just fine to leave it be.

Just my two cents.

P.S.  Your bike is rad.

[theofam]

Traveler, if you're not going to use that starter cover, I'll buy it.  I need an extra one to louver (don't ask . . . yet).

[Zaipai]

Joe,
 Its looking very good. Fantastic job well worth the sore hands..

.: Scott :.

[traveler]

Thanks, guys.

I will keep the starter cover.....it just has a spot where the rust ate through the chrome.

~Joe

[traveler]

My new sprockets arrived today.  Pic is really bad, as my rear sprocket is silver, but looks black in the photo.  Again I went 2 teeth smaller on the front sprocket (15 Tooth).

Also ordered 2 shifter shaft seals from Honda....original is completely shot.



~Joe

[Zaipai]

Looks good.. I am afraid I will run into the same problem when I take of the sprocket cover. Glad you could get replacements..

.: Scott :.

[Ryan 550k]

Also ordered 2 shifter shaft seals from Honda....original is completely shot.

Is this for the leak?  I think I have the dreaded shifter leak as well.

[traveler]

Thanks, Scott.

Alot of guys on here have wrote about changing this seal out.....and I really needed it, so I ordered it online from "westernhillshonda.net".

Ordered 2 instead of one, in case I screw up the first one!  If not, then I have a spare, or can help you out if you need it.

Just how in the hell did a Harley guy fall in love with these old CB's anyway???

~Joe

[traveler]

Also ordered 2 shifter shaft seals from Honda....original is completely shot.

Is this for the leak?  I think I have the dreaded shifter leak as well.

from what I've read, this is a common deal, especially on the 550's.  Read my post above, they can hook you up on a seal.....worst case, go to the dealer and order one.

You know what's killing me?  I really want a K0 CB750 stocker!

ahhh...oh well!

~Joe