Topic: 77 CB550F Upgrade Project "Tighten Up" First Bike and Build

[Michael Wilson]

When it became mine in July of 2010, my 1977 Honda CB550F was sporting some hideous high rise bars, the muffler was no where to be found, and the airbox was replaced by a custom air filter (which consisted of some PVC piping linked together with a pod filter sticking out of the side of the bike). There was also a special switch, wrapped in red electrical tape,  just behind the right rear side cover, which was charged with the noble duty of operating the headlight.









As is to be expected, there was the typical amount of rust, dings, dirt, etc. The seat was torn, the spokes of the back wheels were pitted, the left side cover was cracked, and on and on.

Despite the odd appearance and questionable decision making of the previous owner, the bike was mechanically sound and worth the $750 price tag.

Over the summer I replaced the unique air filter with Uni pods, cleaned the carbs, replaced the torn seat, bolted on a glasspack muffler (which eventually fell off during a ride upstate; I reattached it when I got home), swapped the high rise bars for black clubmans, sured up the front brakes, and did what I could to clean up the chrome so I could just ride for the rest of the summer.

Here is where I ended up at the end of the summer.



I began the restoration/upgrade/tune-up/overhaul/investigation project this weekend.

Here is the plan:
1. Remove and open the engine to replace/repair the cam chain tensioner. (I discovered it was busted during a routine tune-up)
2. Take inventory of anything else in the engine that needs replacing.
3. Clean, lubricate and check measurements on everything that doesn't need replacing in the hopes that I can attain proper compression and timing.
4. Install new turn signals, break light, and battery.
5. Rewire the headlight and remove the silly red switch (I would like to find a headlight bucket with an integrated speed-o).
6. Reseal the forks.
7. Replace/repair the front and rear breaks (currently not confident in the safety of the bike)
8. Boil the rusty tank.
9. Rebuild/rejet the carbs.
10. Remove the gauges.
11. Install clip-ons.
12. Polish and restore all the chrome and give the tank, side covers and frame a fresh coat of paint.

[Michael Wilson]

Liquid Wrench and the impact driver are my new best friends. I stripped a few screws, but all in all the engine came out like a dream.



I only broke one part and its in the area where the rev counter cord enters the top of the engine.


I am not planning on running a tach any longer, so I am not too concernced with this, but I do want to seal up that hole. Anyone have thoughts on a replacement part that will close this off so oil doesn't spew all over everything?

My engine is total mess.




I think this is why my transmission was getting sort of wonky at the end of the season.


I took off the front fender (which I am going to chop), the rear tail light and turn signals.


Next Sunday I am going to open up the engine and do some serious cleaning.

[RContino]

Great looking project man. How far into the engine do you plan on going?

[Michael Wilson]

Balls deep! HAHA. I need to see whats up with that cam chain tensioner, so at least that far. This is my first time, so I don't want to get in over my head. I had fantasies of building a new seat and all sorts of things today....we'll see where this goes.

[Loki047]

Balls deep!

Ding ding ding right answer.   What size bars did you get? Link?

[Michael Wilson]

I'm not exactly sure what size they were. I just bought them on electronic bay. link here: http://cgi.ebay.com/ebaymotors/Black-Cafe-Racer-Ace-Clubman-bars-kz-cb-xs-650-750-850-_W0QQcmdZViewItemQQhashZitem4cf1de51bbQQitemZ330475393467QQptZMotorcyclesQ5fPartsQ5fAccessories#ht_3812wt_939

[RContino]

Nice, I've seen a lot of recommendations to replace the plastic cam chain tensioner and guide. As a fellow first timer who recently split the cases and tore the thing to pieces - figuring out the right way to measure specs, replace and reassemble properly is pretty daunting. In hindsight, if my project was running well before teardown and had less than 30k miles, I'd have kept the cases together and given it a thorough cleaning - then focusing on the mating surfaces, bores, pistons and valves.

How many miles are on the engine? Did you check compression/have any oil leaks?

Although my project is mainly stalled because of the cold weather and lack of heat in my cave, having the thing in pieces has caused me to do a good amount of head scratching. So far I estimate at least $700 in engine components alone. With the expertise on this forum and some patience, though - nothing we can't handle. Let me know if you want to come up to Astoria and see first hand what you might be up against.

[Michael Wilson]

It was running all summer, but I couldn't do a proper tune because of the cam chain. I did adjust the valves though. There is a small oil leak in the space between the sump cover and the bottom of the engine. I think there is about 20-25K miles on the engine. There are so many other issues with the bike other than the engine too. Electrical, suspension, breaks, wheels, not to mention paint. I am pretty nervous about cracking it open, but I truly feel like its necessary. I really want to do the minimum amount of fiddling when I am in there. I am going to take you up on that offer to visit. Message me your address and maybe I can make it up one of these weekends.

[Michael Wilson]

Had another beautiful day today. I really wish I had been riding, but alas...more tearing down to do. I need to make a list of parts I need.

I started by removing the front wheel, bars, headlight, and brakes.



I love that the brakes come off as one unit to avoid bleeding them at this moment. I will install braided metal lines to replace the rubber lines that come stock. I am going to keep my headlight until I find just the right one with an integrated speedo. So for now...no gauges. I found some affordable clip-ons online as well, so if anyone wants my clubman bars, let me know. The front wheel is in pretty good shape. I think the PO replaced the disc on the front wheel.

Next up: forks. Nice and easy really.



Rookie mistake...I dropped some of the ball bearings. I think since my forks are off it would be a good time to clean up my steering as well. Any advice on upgrades from the stock set up?

I went right into after that. Removed all the wiring, the rear wheel, shocks, stands, swing arm, battery holder basket bracket thingy, rear brake linkage rod (I am pretty sure my vocabulary is making some of you cringe). Basically...everything came off today.



The rear wheel is rusted out pretty bad. Its going to take a lot of elbow grease to get it shining again, so I might be lazy and just get a used one thats in better shape. Any thoughts on where to pick up used rear wheels? I am going to keep an eye out on eBay. The only thing that was a bit tough was the center stand. I guess the mounts on the frame are tapered, which forced me to pick up the trusty mallet. A few more than gentle taps and she was off.

So there is it. Torn down to the frame.

All the pieces labeled.



Everything neatly tucked away.



Ready for upgrades and paint. I have decided to paint the frame gold and everything else black. I get paid today so I am going to be ordering turn signals, bars, and a tail light. I'm not sure if I am going to do body work (ie chop my fenders and prep them for paint) boil my tank and grind that down, or work on replacing my fork seals.

Any tips on which order I should start upgrading and reassembling would be appreciated.


PS. I don't think I am going to crack open the engine at this stage. It was running last summer. I want to ride soon. I don't want to create unnecessary problems. so, I am going to clean it up from where it is now (inside the crank case and outside everywhere else) and replace the gasket on the sump cover. I know its not perfect, but it will run. In the meantime, I am going to keep an eye out for another 550 engine in good shape that I can clean and rebuild at my leisure while I ride all summer. Rebuilding carbs and doing as much tuning as I can should keep me going until my secondary engine is completed and ready to be swapped. Good plan, yes?

[wannabridin]

Rookie mistake...I dropped some of the ball bearings. I think since my forks are off it would be a good time to clean up my steering as well. Any advice on upgrades from the stock set up?

upgrade that to some tapered bearings!  those ball bearings are 30+ years old and should be discarded immediately.  tapered bearings will distribute the stresses from the front end over a greater surface area, and they'll hold their grease a lot better for a lot longer!  you'll notice better handling and it will track better from stability increases...  it's a WELL worthwhile upgrade for a little cash!

good looking build so far tho!  digging the electrical tape over the headlight!   

[FunJimmy]

Lookin good so far.

Don't let that engine intimidate you though.
Get or download a manual, if you don’t already have one and go slowly.

When I split my cases, I made dam sure I didn’t upset the tranny, and everything went back together perfectly.
You can even take a good look at the crank bearings and see if there is visible wear to gauge things a bit.

Have fun.
FJ

[Michael Wilson]

upgrade that to some tapered bearings!

Something like this? http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-streetfighter-motorcycle-parts-honda-cb350-cl350-cb360-cl360-cb450-cl450-cb500-cb550-cb750-steering-bearing-neck-kit-122-1011.html

Don't let that engine intimidate you though.

Thank you for the encouragement. I change my mind daily about opening it up. It is possible to open it and do just a little work without disturbing too many parts correct? All I really want to do is fix my cam chain tensioner.

[captaincrash80]

Your current plan is about the same as mine is. I have a running motor in my bike right now but I also have have one that's torn down to empty cases sitting in a cabinet in my garage awaiting a rebuild. It's nice having spares 

[FunJimmy]

upgrade that to some tapered bearings!

Something like this? http://www.dimecitycycles.com/vintage-cafe-racer-caferacer-bobber-brat-chopper-streetfighter-motorcycle-parts-honda-cb350-cl350-cb360-cl360-cb450-cl450-cb500-cb550-cb750-steering-bearing-neck-kit-122-1011.html

That's the type you need. All Balls Racing has a great kit too.

FJ

[goaarongo]

Looks like a fun project.  +1 on not being intimidated by the motor.  Just take your time. 
I'm curious about where you got the name "Tighten Up" from... any significance to it?     

[Michael Wilson]

Its good to know I'm not alone. This is like moto n00bs anonymous! haha.

FJ - Thanks for the tip.

I'm curious about where you got the name "Tighten Up" from... any significance to it?

Its just the working title. I am tightening up the bike and its my current favorite song (check out the Black Keys to have a listen). Since I have decided on a color scheme I am considering changing the name to "Gold Rush".

[goaarongo]

Nice - glad to know I'm not the only one rocking to the Black Keys in my garage.   

2 cents on the color:  I hate to see the blue and gold go - I always loved that combo.  If the paints not to faded or messed up, I'd consider keeping it.  A touch of the original here and there can really make a custom bike look great.     

[Michael Wilson]

I am bored at work today so here is the complete list of things I need to purchase for my project.

• Front brake pads
• Braided brake hose
• Clip on bars
• Right and left controls
• Grips
• Fork seals
• Tapered steering bushings
• Progressive suspension front fork spring
• Seal puller
• Bar end turn signals
• Electronic relay for LEDs
• Headlight bucket with integrated speedo
• Headlight brackets
• Probably a load of new wires
• Black paint
• Clear coat
• Exhaust wrap
• Cam chain tensioner
• Valve stems (possibly)
• Piston rings (possibly)
• Replacement gaskets
• Something to replace my rev counter. (I broke the plate where this enters the engine. Thoughts)
• Carb rebuild kit (including floats)
• Main jets
• Pod filter oil
• Battery
• Spark plugs and wires
• Rear wheel
• Tail light
• Sidecover decals
• Bondo
• Chemicals to boil the tank
• Swing arm bushings
• Throttle pull cable
• Points cover
• Lots of cleaners and sandpaper to get her nice and shiny

Hmmm thats a long list.

[mblessing]

You've got some balls for being a noob!  I feel like a chicken #$%* for buying my first bike in ok shape.  I just picked up a '76 CB550 K for 1600 in pretty descent shape.  At least it seems to run strong (for what a noob can tell).  I wish I had a garage of my own to work in though.  Great pics, giving me ideas...

Do you know what is involved in replacing the standard brake light with something a little sleeker, maybe an LED?  I saw you listed "Relay for LEDs"

[78 Basketcase]

Don't worry about tearing the top end apart. You'll be surprised how simple it is. I'm new to these bikes and I'm no mechanic. I currently have 2 550's with the top end of the motors disassembled. The thought of splitting the cases intimidates me a little and I can't really find a reason to crack em since I don't know what to look for. I bought both bikes with the engines being off the bikes (one had sat forever and was seized.) I'm waiting to save some money cuz both top ends need to be bored and fresh pistons/ rings installed. Plan on assembling it myself. if you need a set of standard size piston rings I have a new set to sell. I'll be watching your project. As soon as I get some cash I'll start my own project thread too. Oh... I've been rocking The Black Keys too!

[Michael Wilson]

mblessing: Thanks. Only one way to learn and thats by reading this site and not making the same mistakes as others. As far as the LED goes, I have not tackled that problem yet, but my friend put LEDs on his Harley and he needed a new relay. I am lucky to be friends with a guy who is great with electrical stuff, so I will be relying on him for advice when I get there.

78 Basketcase: Thanks for the encouragement. Keep checking back, I will have some new progress photos this week. I've been cleaning an polishing before I crack anything open.

[Michael Wilson]

Today was engine cleaning day. 5 hours of tedious labor and I'm not done. I think I made it 2/3 of the way. I used standard oven cleaner to cut through the massive amounts of grease and grime on my engine (after plugging the holes of course). That with an array of scrub brushes did a decent primary cleanup. I then went at it with a 4" fine needle steel wire wheel and a fine needle cup brush to "polish" my breather cover, crank case cover, valve cover, etc. Its not perfect and I think i scratched a lot of the surfaces (a brass wire brush and cup brush probably would have done a better job), but I am happy with the result, thus far. It's certainly cleaner.

Breather cover. A little scratched, bot not bad.



Rear suspension. This didn't go so well. These might be stuffed and I think I'm gonna replace them.



Crank case cover.


Didn't really need to clean the inside, but why not.



Valve cover.



Shes looking better.


Points cover might be dented as all hell, but at least it shines,






I spent a lot of time today trying to clean and polish between the cooling fins and to save my rear springs. Next week I am going to get some better brushes to make life easier when it comes to getting between the fins. Overall, the progress was good, but I have a long way to go. 30 some-odd-years of dirt and neglect takes a long time to cut through.

This has been the least fun day so far. I'm really looking forward to doing paint and body work, cuz this cleaning stuff is boooooooring.

[MasterChief750]

i had some luch with hammering out a large dent in my points cover.

[nk140]

i had some luch with hammering out a large dent in my points cover.

ditto

[Michael Wilson]

How'd you guys hammer out your points covers?