Topic: 78 CB550K From Rust to Riches

[CrashBar]

*******************October 2018 Update - in perhaps the longest build hiatus in SOHC history, my CB550 has been tucked away for the last 7 years while other projects and bikes came in front of it.  Well, I'm back and want to get this on the road for spring*****************************

*******************Spring 2020 Update - Still at it, Summer 2020 back on the road?**************************

2011 - So I'm trolling through bikes for sale on Craigslist about 18 months ago and come across a 78 CB550K.  Usual story, ran great, left outside, lots of surface rust, brakes frozen, etc etc.  $600 delivered. Well, I spend $400 just to get my CB350f delivered from Ohio, so this is just like getting a bike for free.   And I'll be able to use all the tricks I've learned on my 350, plus scavenging on ebay,  to get this up and running.  A few emails later, the 550K is being unloaded in my driveway.  The seller clearly has an attachment to the bike and is happy to see my CB350f sitting in the driveway, as it appears to be in good hands.  We will see.

Here are the pictues from the PO.  It is all there except a recovered seat and pods.


 

[CrashBar]

Lots of scrubbing and sanding, and rattlecan black  to the frame.   A set of decent fenders and shocks and taillight - 148 bucks with shipping on ebay.   Starting to look decent.   Up to 748 bucks.    Good news is that the tires are new and in good shape.  Even better news is that with a charge and some starter fluid it fires right up. 




more to come...stay tuned.

[CrashBar]

Re-reading Perer Egan's "300 Dollar Jewel" I realize that inflation is a terrible thing but I could deal with a "1500 Dollar slightly crusty Jewel".   The front brake caliper was frozen, so I stripped them down, did the grease gun trick, and installed a piston and speed bleeder.  The lines and M/C look like trouble but one thing at a time.  55 bucks.
 

[CrashBar]

The pods have to go, and I buy two separate sets of airbox parts on ebay, finally end up with enough good bits to get a complete airbox setup with all the hardware, with lots left over for the build-completion ebay sale. 81 bucks.  I also score a pair of decent black side panels for 28 bucks, and throw the original re-spray ones in the to-be-sold pile.



Thats a grand total of 900 bucks. 

[CrashBar]

The wheels and spokes are shot through with rust and corrosion.  I manage to get a nice set on ebay for 125 bucks, and swap over the tires and install new tubes.  $125 bucks. I find a nice set of fork ears for $25.   Thats $1050, but I've got $100 bucks worth of take offs with the pods, airbox bits, and side covers.  So $ 950 it is.  We are starting to get some where.  Now for a decent seat and tank.

[CrashBar]

I find a decent tank (clear coat is peeling, but I can deal with that) for $75 and a NOS seat still in the box for 150.   Major splurge on the seat but it makes the bike, and I figure the old seat and tank are worth $100.  Plus a chrome points cover for 35.  Turns out the master cylinder is shot and the lines look like crap.  I order a modern M/C  from MikeXS and braided steel brake lines from Z1.   Looking at $1300 bucks net at this point.  Photos from last week.





I've changed the oil and plugs, need to set the valves and check the timing.  Once the Front Brake is set it will be time for a ride.  Stay tuned.

[TwoTired]

Lookin' pretty nice!

[Grnrngr]

Kinda hard to tell from a pic, but I thought the green looked pretty good too...

[CrashBar]

 As I updated in the first post, my CB550 has been tucked away for the last 7 years while other projects and bikes came in front of it.  Well, I'm back and want to get this on the road for spring.

I rolled it out yesterday and gave it a through cleaning and took inventory of what still needs to be done. I also pulled the left side exhaust and spent a few hours on the wire wheel and polishing wheel on my bench grinder, as the pipes were still a cosmetic mess.   I'll post some updated pictures after the weekend.

I could use some recommendations on where to source the parts below, I've been out of the loop on honda parts for a while.

To be done:
Replace the clutch cable - it was probably never great, totally frozen now. Purchased and hooked up the lever end, need to attach engine end.  Done March 2020[/color]
Oil Drain Plug crush washer.DONE  Added 1 quart of oil, going to make sure that the missing crush washer was the issue.
Buy New Grips (want something stock looking) Done
Buy / Install Rear Tube  Have tube Done with new rear tire March 2020
Buy / install new Battery DONE
Master cyl maybe - I bought a more modern one from Mike's XS but the cover is missing, need to dig around.Have Rebuild Kit for stock M/C
Various rusty fasteners Ongoing...
Clean out old gas Done March 2020, petcock too
Carbs - not sure what to expect, they were ok in 2011 but might need a refresh.  I rebuilt my CB350 but might send these out.
Paint headlight bucket black - Done.
Remove and get the rust off the right side exhaust.  Done, still figuring out what to do with pipe 4, see below 1 pre-owned pipe purchases, $125, all 4 installed March 2020
Paint the headers (hi temp silver?) as they are pretty rusty even after removing what is there I know it will just re-rust.
Weld some pinholes in one pipe and weld a small patch on the other ( at the pipe / muffler junction).
Polish / clean the engine.
Replace at least one rotten carb / airbox boot (I may have spares) DONE
Start it up!

[CrashBar]

This week's progress
Pulled the exhaust system off, wire wheeled and polished all of the components of the left side pipes.  Looks much better.  Need to get some high temp silver to paint the flanges (the heat sink looking thing) DONE and the header pipes down as far as the muffler, and the back side of the muffler.
Install new grips Done
Replaced the clutch lever bolt (rusty) DONEand 4 turn signal bolts (rusty) DONE
Received the battery (Scorpion YT12C) but given that temps are dropping I'll hold off installing until I'm ready to test the electrics Done March 2020


Next
Wire wheel and buff the other two pipes. Done Take one to my welder to put a patch where it is rusted out (where header meets muffler).  Pipe Replaced Instead
Hi Temp Silver the header pipes and flanges. DONE
Replace one rotten airbox boot (I found some in my stash of CB parts) DONE
Put the washer on the Oil Drain Plug Done
Replace rear tube (found in my CB stash too) - I'll put the hub on the buffing wheel while I have the wheel off. Done with new rear tire (front done too) March 2020
Install the two screws that hold the headlight rim to the bucket Done.  Replaced the adjustment screw, spring, and nut as well.
Drain any gas, check the condition of the tank, clean the petcock.  Done March 2020


Need to order next
Clutch cable DONE
Negative Battery Cable (corroded) DONE
Battery hanger Bolt and Nut (missing) Replaced March 2020
4 Philips head screws in top of valve cover (rusty)
Swing arm pivot washer (rusty)  Purchased  need to dig my larger sockets out
Foot brake pivot bolt (rusty) Done
Headlight bucket bottom bolt (missing) Purchased
Headlight adjustment screw Done
Nuts and 3 washers on turn signal bolts Purchased
If there is some kind of gasket there the head pipes go into the head (like my CB350f) I'll need those too. DONE

[calj737]

Need to order next
4 Philips head screws in top of valve cover (rusty)These are JIS, not Phillips, just so you know.
If there is some kind of gasket there the head pipes go into the head (like my CB350f) I'll need those too.Copper crush gaskets are installed between the header and exhaust port. Dig the old ones out before you install new ones.

[CrashBar]

Yes on the JIS, thanks. I’m ordering from the parts list at Bike Bsndit so it should be all good. I got a set of 5 JIS screwdrivers too to keep from stripping them.

I’ll put the crush washers on my shoppping list.

[754]

Just oil the clutch cable and reuse. Clean up the battery cable. .
 Hang the cables and shoot some oil in.  Some use a small baggy and elastic..  on yop of cable and put oil in there.
 Linking cable Back and Forth may free it up..

[RAFster122s]

JIS screws, at least modern ones will have a dot on the screw head. Your screws for the handlebar controls are also JIS.

Calj, have you invested in JIS taps? If so, Where did you source them from?and how much are they in the ballpark numbers?. 
Are your ARP machine screws available in JIS?

[RAFster122s]

Honda cables if you need new cables are worth the extra money. They operate smoothly longer than any of the aftermarket and are made or much better  raw materials. That fact I learned from the forum after being here a while after I had bought new Motion Pro Cables.

[CrashBar]

Did the grease gun trick on my caliper.  Lots of pitting after I wire wheeled the corrosion.

Replace or re-use?  Not sure how critical the surface finish is.  If replace, OEM ($107?! at bike bandit, half that NOS on Ebay), Ebay knock off special, $18,
  or is there an aftermarket version that is superior?

I've already bought the seal.

[calj737]

Member Godferrey sells a phenolic replacement. That’s your ticket.

[SOHC4 Cafe Racer Fan]

Did the grease gun trick on my caliper.  Lots of pitting after I wire wheeled the corrosion.

Replace or re-use?  Not sure how critical the surface finish is.  If replace, OEM ($107?! at bike bandit, half that NOS on Ebay), Ebay knock off special, $18,
  or is there an aftermarket version that is superior?

I've already bought the seal.

Do NOT re-used that piston.  It will just destroy the seal.  Along with Cal, I'd recommend replacing it with the phenolic piston -- it will not corrode.

[CrashBar]

Thanks, Phenolic is what I remembered, I think I have one floating around that I bought for my 350/4 but never installed.  Ordered just now.

[CrashBar]

I'm about 2/3s of the way throughcleaning up my exhaust.  Here is what they look like now.

One has a pretty good hole in it, I am going to take it to my welder and see if we can patch it.  Its structurally sound, surprisingly.  Any recommendations on how to weld it? It's underneath so it does not have to be too pretty.

Thinking of spraying the top of the head pipes, and the hidden parts of the muffler around the brackets with the same hi temp silver I did the flanges with, otherwise the pitting and surface rust is going to spring back up.

[CrashBar]

Here are some "before" shots.  Ugly.  A few more hours at the buffing wheel should get me pretty far.

[calj737]

MIG it. But your welder shuold expect it be a major PITA due to internal rust. I’d spot tack it and not stitch it. Might get it to go.

[CrashBar]

Caliber cleaned, new gasket, new piston, new pads. Going to paint the caliper first, I wire wheeled it down to bare aluminum.

Piston is very snug to the seal, some brake fluid as lube on the way in?

[calj737]

...and make sure the seal groove is very, very clean.

[CrashBar]

Good point on the seal groove. I think it’s clean but I’ll put my boroscope in there tomorrow and post some images.

Decided to rebuild the master cylinder. Waiting for the kit now. Good info on this site for getting that damn clip out