Author Topic: 1978 CB550  (Read 3512 times)

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Offline Gregory Groth

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1978 CB550
« on: May 17, 2011, 05:57:33 AM »
Around 6 years ago, my brother gave me a freebie 1978 CB550K that someone had given him.  Supposedly the bike ran fine, but had some wiring issues, and ended up parked for an extended period of time.  Around the time I got it, I had replaced the bad ignition switch, and rebuilt the carbs to try and get it running.  I screwed up the float settings in two of the carbs, and the project got shelved, and it's been sitting on my patio ever since.  My sons are older now, and were showing interest in turning wrenches, so we pulled out the Honda, and decided to go through it front to back with a fine tooth comb, and teach them something about how vehicles work.

The bike is a 1978 Honda CB550K.  The stock airbox was missing, replaced with pods when I got it.  Other modifications that were done by the PO include replacing the stock 4 into 4 exhaust with a 4 into 1 from a CB550F, and installing a set of carbs from a '74-'76 CB550.  I replaced the seat with an earlier model, as the original seat pan was a rusted mess (the replacement seat still needs recovering).

To date, we have accomplished the following:
1.) Tracked down and a replaced bad ignition switch, replaced a bad starter solenoid, replaced a melted fuse box, fixed two corroded grounds, replaced the handlebar controls to fix two broken switches, and cleaned up the mess in the headlight bucket so that all electrics work properly.
2.) Rebuilt the front brake whose fluid had crystalized into something other than fluid, including rebuilding the master cylinder & caliper.
3.) Replaced the front wheel bearings.
4.) Cleaned and packed the headset bearings.
5.) Rebuilt the forks.
6.) Rebuilt the rear brakes, replaced rear wheel bearings.
7.) Replaced the swing arm bushings.
8.) Pulled the engine, and completely disassembled it.

Next steps:
1.) Replace the primary chain & cam chain.
2.) Replace the piston rings.
3.) Hone the cylinders.
4.) Clean / lap the valves.
5.) New points / condensers.
6.) Reclean carbs.
7.) Put it all back together.
8.) Go through the charging system.
9.) Hopefully locate a stock airbox.
10.) Get it running, and tune it.
11.) Replace the tires (this is last on the list in case this project ends up on extended hiatus again)
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #1 on: May 17, 2011, 05:58:37 AM »
More pics.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #2 on: May 17, 2011, 05:59:21 AM »
More pics.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #3 on: May 17, 2011, 06:00:08 AM »
More pics.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #4 on: May 17, 2011, 06:01:38 AM »
Here's where we finished up last night.  We reinstalled the swingarm with new bushings.  Installed the rebuilt rear wheel with new sprocket, and connected the rear brake.  Now on to the engine.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Tom in Newcastle......Ontario

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Re: 1978 CB550
« Reply #5 on: May 17, 2011, 06:23:58 AM »
Looks like fun............approx where are you located
1978 cb 550k......stock,my first re-build


Loud pipes suck.......

If you buy something.........pay for it !
If you sell something .......ship it !
If you say you are going to do something......do it !
If you have a question about something......ask it !
When the seller answers ........let him know whether you still want it or not !
If you receive something .....let the seller know you got it !
If you get something and are happy/un happy with it .....let the giver/seller know !
If you have any kind of issue,shipping/receiving/quality/price/shipping charges etc !
Communicate

Offline Gregory Groth

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Re: 1978 CB550
« Reply #6 on: May 18, 2011, 10:42:39 AM »
Located in NW Chicago.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #7 on: June 28, 2011, 10:38:46 AM »
Finally got some cash together to order some parts

This project got derailed about a month ago when I pulled the valve guide seals off the head, and discovered that each and every valve guide was cracked.  My first attempt at buying a replacement off of Ebay showed up in a box with the valve cover bolted to the head.  Of course the valve cover wasn't installed correctly, and I immediately found another cracked valve guide and a bent valve.  Sent that one back for a refund, and bought another off of Ebay (this one did not include the valve cover - so I crossed my fingers that the valve guides wouldn't be mangled).

Also managed to do the following:

1.) Repainted the engine cases with some high heat rattle can silver from Menards
2.) Replaced the primary chain, and reassembled the bottom end with no spare parts left over.
3.) Honed the cylinders, cleaned & painted the jugs.
4.) Cleaned the pistons and installed a new set of rings.
5.) Disassembled the new head from Ebay, and ensured that the valve guides were OK, and that none of the valves were bent.

Next on the list is to decarbon / clean the head and valves.  Paint the head & valve cover.  Lap the valves.  Install the head, camshaft, new cam chain, valve cover / rockers.  Adjust the valves.  And spend way too much time polishing the severely corroded side covers to try and make them presentable.

Slowly, but surely.
« Last Edit: June 28, 2011, 11:13:17 AM by ggroth »
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #8 on: July 03, 2011, 07:23:54 PM »
2nd head I purchased through Ebay appears to be usable, so I decarboned the head.  Cleaned the valves.  Lapped the valves.  Cleaned up the ports a bit with a dremel.  Installed new valve guide seals.  And put the whole thing back together.  Just need to paint the head, the valve cover & the breather cover, and put it all back on the engine.
1978 Honda CB550
1968 Suzuki T500 Cobra

Offline Gregory Groth

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Re: 1978 CB550
« Reply #9 on: July 03, 2011, 07:25:02 PM »
A couple pics of the engine, and the CT70 my 13 yr. old is working on..
1978 Honda CB550
1968 Suzuki T500 Cobra