Author Topic: 77 CB550F Upgrade Project "Tighten Up" First Bike and Build (Read 10566 times)

Michael Wilson · « **Reply #25 on:** March 21, 2011, 11:29:13 AM »

More cleaning!

Done!

I bought a set of thin brass and steel wire brushes, but they just wore down and broke so I just brushed it and cleaned with some oven cleaner, a spray bottle, the wire wheels and a scrub brush. Looks like step one is done.

Step 2: Rebuild and clean the forks. I ordered my fork springs, oil seals, steering bearings, and a fork seal puller. Next weekend, its the battle royale with those suckers. Also, I'm dropping my frame at the sandblasters to prep it for eventual gold powder coating.

Michael Wilson · « **Reply #26 on:** March 27, 2011, 05:19:46 PM »

Dropped the frame at the sand blasters on Friday. I hope I can get it into the paint shop and back to the garage by the end of the week cuz things are starting to move along with this project.

Stripped the tank today.

A little concerned about the rust here. It was pretty intense and I think there might be a tiny hole in there. I am going to seal it up with a little bondo.

I used the angle grinder with a 60 grit sand paper wheel to do the bulk of the work. For the tough spots I used Zip Strip. What an amazing product. Took off the remaining paint in no time. I highly recommend it.

I wanted to do the chemical treatment to the inside this week too, but I realized my petcock is leaky. I new one is on the way along with a tail light, clip on bars, bar end turn signals, fork gaitors, and the parts for my fork rebuild that didn't make it this week.

The goal this week is to get the frame back, treat the tank, rebuild the forks, trim the fenders and prep the wheels for paint. I have a guy lined up to handle my tank, fenders, and wheels. Also need to trim, strip and polish the upper fork yolk next weekend.

MasterChief750 · « **Reply #27 on:** March 27, 2011, 06:42:59 PM »

take the petcock out and put a rubber plug in the hole, if you are using an acid to clean the inside of the tank it will eat the aluminum of your petcock and release h2 gas in the process

RContino · « **Reply #28 on:** March 28, 2011, 01:20:09 PM »

I second the rubber plug... you may have to take the plastic filter thing out too (might have to destroy it and get a new one in the process) - I didn't realize it was in there until it was too late, came out with the acid as a nasty molten goo. I couldn't find a plug to fit inside but they sell little rubber caps at home depot for 50 cents or so - I think it was the grey or yellow one (1/2"?) that fit nice and snug... they're in a drawer in the nuts/bolts section.

Where'd you get the new petcock from (what kind, size, how much)?

Michael Wilson · « **Reply #29 on:** March 28, 2011, 01:28:28 PM »

I got my petcock from Dime City http://www.dimecitycycles.com/vintage-cafe-racer-bobber-brat-chopper-custom-motorcycle-carburetor-fuel-tank-parts-universal-m14-fuel-petcock-18-7167.html I'm not sure it will fit, but for $27 it was worth the risk.

UPDATE: The petcock doesn't fit. Its a 14mm nut to attach it tot he tanks and it needs to be a 15mm. I am going to try to find a converter because i like the new part and I don't want to just waste it.

Michael Wilson · « **Reply #30 on:** March 31, 2011, 01:38:08 PM »

OK. I need some help. I need to replace my rear shock absorbers. They measure 12.5" eye to clevis. I would like to replace them with the same measurement or something slightly lower. I can't find the right part anywhere in the links from the FAQ page (except http://www.servicehonda.com/look-up-parts/03 and they aren't exactly cheap). Any thoughts on where one can purchase this item? (Parts N More has a nice 11.5" set for $80, but they are eye to eye.

Not clevis). Thanks guys.

Michael Wilson · « **Reply #31 on:** April 03, 2011, 04:18:39 PM »

I got my frame back from the powder coater.

Removing steering bearing races from the frame. I simply caught a piece of steel on the lip of the race and tapped around in a circle and they slid right out. I had my local shop remove the bottom race from the stem.

I trimmed the handlebar bracket off of the top yolk.

I cut and shaped my front fender.

I cut and shaped my rear fender and mocked up the new tail light.

Rebuilding forks.

Took a little thinking to get the fork gripped properly to crack upen the top filler nut.

Removed the fork oil seals with a fok seal puller. It still damaged the fork boots a little. Is this going to be a problem?

I replaced the old springs with new progressive springs. I replaced the old oil seals with new ones using a slightly tapered piece of PVC pipe.

The first one was tough because I hadn't tapered the pipe and I wasn't sure where it was meant to seat. I pounded on it for some time. I really hope I didn't damage it. The second one I got smart and tapered the pipe just slightly. I few taps and it went right in. In total it took about 2 hours and I saved about $50 on a oil seal seating tool.

I took all my parts to the paint shop and we got through the primary coat on everything except my left side cover. I need to have that repaired with a little fiberglass in the next week. I hope to have these parts all painted by the end of the week and ready for reinstall.

I only volunteered to paint the underside of one fender and my side stand.

Better to leave the important parts to the pros.

I am really excited about the progress this week. A fresh coat of paint makes everything better. Next weekend I am going to install the new steering bearings and get some stuff back on the frame to see how its all going to look.

Stev-o · « **Reply #32 on:** April 03, 2011, 06:14:20 PM »

What color is the tank going to be? Looks good...

78 Basketcase · « **Reply #33 on:** April 03, 2011, 10:31:54 PM »

Looks like you're making progress. What's the final color scheme gonna be? Are you painting the motor too?

Greggo · « **Reply #34 on:** April 03, 2011, 11:26:00 PM »

Nice work!!

Michael Wilson · « **Reply #35 on:** April 04, 2011, 05:45:58 AM »

The tank, fenders, and side covers are going to be a nice glossy black to match the luster of the metallic bronze frame. The headlight bucket, stands, triple trees, and forks are going to be a satin finish. I think shiny forks would be weird. I won't be painting the motor or the wheels this year. I am satisfied with the polishing and cleaning I have done on the engine to date and I am getting a new back wheel which is far better shape then my current set up. Those parts will be chrome until next winter when I can spend some serious time working on just the engine, but the chrome is in good shape there and I think this is all going to look pretty cool when its back together. Thanks for checking it out everyone.

Nortstudio · « **Reply #36 on:** April 11, 2011, 11:40:29 AM »

Nice progress! Where are you in Brooklyn? I'm in Williamsburg. Working on a '76 cb550k....

What process did you use to chop the front fender???

78 Basketcase · « **Reply #37 on:** April 17, 2011, 10:29:44 PM »

Any updates on your project?

Michael Wilson · « **Reply #38 on:** April 18, 2011, 05:10:44 AM »

There has been some moderate progress over the last two weeks. I finished painting on Saturday, but I don't have any photos of the finished parts in black yet. They came out great and you'll just have to take my word on that...for now.

I opened up my cylinder cases to replace my cam chain tensioner and the 30 y/o gaskets that are leaking. Taking that stuff apart wasn't too bad, but my cam chain tensioner is a problem. I can't free the lock nut from the adjuster screw. I need to cut it off. So I started dremmeling.

But I stopped because I think it might be smarter to cut laterally through between the nut and washer here:

Thats the word I got from one person in another thread. It is still up for a vote.

I went to my buddy Ryan's (rcontino) garage on Saturday too and picked up a nice lot of replacement parts. Suspension, front and rear sets, functioning cam chain tensioner, points and points cover, and a few other things. I am sad to see him parting out his project, but I am glad I found some otherwise expensive parts in a friend's garage.

Thats it for now. Next weekend I will finish taking care of the cam chain, hopefully have replacement gaskets so I can tidy up the engine and bolt it back down, and take all my nice new shiny parts and mock up the new look of this project.

Nortstudio · « **Reply #39 on:** April 18, 2011, 05:23:07 AM »

Looks like it's coming along. I'd love to stop by next weekend and check it out firsthand.

Good luck with that lock nut. After cutting the screw driver slot, it still wouldn't move? Total PITA!

Michael Wilson · « **Reply #40 on:** April 23, 2011, 05:58:14 PM »

So I got steering assembled. The tapered bearings went in without any sort of freezing or oven heating what-so-ever. Everything lined nicely and it feels great. I also got all my parts from the paint shop and over to the garage for the mock up. I love that it looks like a motorcycle again.

Sorry for the crap photos. Its really dark and rainy and my garage mate was using all the good lights today.

And I know the clip-ons are mounted backwards and the headlight brackets are upside down, but the bolts on the bars were touching my tank when the steering was turned all the way and i wanted to see how those brackets looked reversed. I still think I am going to mount the bars above the trees, but that will mean cutting my gators to fit. I dunno. I have a long way to go but I am so happy to be mocking things up and not just imagining things.

goaarongo · « **Reply #41 on:** April 25, 2011, 05:25:46 PM »

You have turned a corner for sure - starting to look good! Keep at it.

Nortstudio · « **Reply #42 on:** April 25, 2011, 05:45:05 PM »

That is looking damn sharp! I'm around this weekend if you are. Love to see it first hand and lend a hand if you need it.

Michael Wilson · « **Reply #43 on:** May 01, 2011, 07:28:41 PM »

LONG day in the garage on a beautiful Sunday in NY. The best/worst thing about my garage is that it is located on a very busy street. Lots of visitors. Lots of girls around. And lots of my friends cruising by or stopping in to say hi. I love company, but man the weather is aces and I am itching to get back on the road.

Progress report:
1. Cam chain tensioner replaced and fully functioning.
2. Cylinder head and cylinder cover gaskets replaced.
3. Forks filled and sealed.
4. Front wheel is on.
5. Back wheel loosely in place.
6. Center and side stands are on. (its up to a rolling frame now. shes on her own two feet again.)
7. The engine is sealed back up and ready to mount in the frame next chance I get.

And now...a word of advice. If your cam chain tensioner is broken and there is no other reason to get into the engine...take it to a professional. The amount of stress, confusion and labor that went into changing that part would have been much better spent elsewhere on this project. But in the end, the job is done. I just hope I didn't muck anything else up in the process. I have to admit, I am sort of petrified that maybe I've done more harm than good. Considering how many times I had to use the rubber mallet to get things to go back together I am going to be really nervous the first time I fire her up.

A funny thing happened. I put the entire cylinder case back together and realized the cam chain guide was in backwards. So I had to take it ALL apart and put it BACK again. *face-palm*

Anyways, I've got no fingernails left and I truly hope I put it all back together properly. Especially the cam shaft. The Haynes manual was a bit confusing about how the notch in the cam shaft and the cylinder head plane should line up. The picture in the book has the notch to the right and the knobs on the cam shaft in the upward position. However, when I lined up the notch to the right, the knobs where in the downward position.

So I decided to line the notch up on the other side so the knobs where in the correct position. Does that seam right?

PS thats at TDC on pistons 1 and 4.

I am going to need to find out about that for sure otherwise my timing will be off and thats the whole reason I opened my engine in the first place. Otherwise, everything else went smoothly.

Here are some photos of what I mean.

The two diagrams I was consulting:

How I decided to set it up.

Michael Wilson · « **Reply #44 on:** May 15, 2011, 12:29:18 PM »

Success. I readjusted my valves and finally FINALLY got to use my cam chain tensioner! With that, my adventures in engines has come to a close....for now. So back in she goes.

It feels like a huge step to remount the engine.

Next up I will be working on my brakes. New braided hoses, shoes, and pads are all on the way. Then I will be reattaching the chain getting everything nicely aligned and reattached (sets, shifter, brake pedal, battery, etc) New bars are on the way as well. I didn't like the ones I ordered so I have something a little more adjustable on the way. In the next week or two I hope to have all the controls and more or less everything back on the bike so I can begin dealing with the wiring harness and finally rejetting and cleaning the carbs. Wrap the pipes. New muffler. And she (fingers crossed) will be ready to fire up.

Its so close I can almost taste it.

Nortstudio · « **Reply #45 on:** May 15, 2011, 12:55:02 PM »

Congratulations! Looking amazing. Shouldn't be long now...

RContino · « **Reply #46 on:** May 16, 2011, 07:31:54 AM »

B-e-a-utiful.

Sledgehammer · « **Reply #47 on:** May 16, 2011, 08:07:31 AM »

You have new bars that are a little more adjustable? I can´t wait to see what you got on the way

DanielB · « **Reply #48 on:** May 16, 2011, 09:20:37 AM »

It looks to be coming along nicely, great work.

Michael Wilson · « **Reply #49 on:** May 20, 2011, 09:41:43 AM »

OHHHH the new bars just came in the mail. They are AWESOME!!!! Fitting them on this weekend along with new brakes. Thanks for the words of encouragement.

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Author Topic: 77 CB550F Upgrade Project "Tighten Up" First Bike and Build (Read 10566 times)