Topic: CB550 revamp

[dmonday]

That is one nice looking bike!

[deafcaferacer]

Also, I picked up the upholstered seat pan this evening.  Leather.  Sweet!  Now, just have to figure out how to do the grips in the same leather...

You could just cut long narrow strips of that leather, spray adhesive on the bottom and spiral-wrap the handles like you would a baseball bat or tennis racket, keep going until you go off the handle, cut off excess, then cap with a thin strip of heat shrink so the ends don't fray and unpeel. Just my .02

[spdygnzlz]

Thanks dmonday! 

deafcaferacer, I'll probably either do that or stitch them on.  I figure that's the final detail once everything else is sorted.  A buddy of mine is also going to make me a small tool pouch with the scrap leather I have.  When I've gone this far, I figure why not?!

[spdygnzlz]

Finally had a few hours to work on the punch list I have for the bike.  finished my electrical hookups. mounted seat, wired headlight etc. I turned it over for a little while using the kickstart with the ignition off to get the oil circulating.  Then I poured in some gas, turned on the ignition and pushed the start button...

It turns over...but nothing, suddenly not sure it's getting any spark.  Also not quite sure I have prepped it properly.  I checked my wiring from the points up to the Hondaman ignition, to the coils.  It looks correct.  But then, that's when I noticed the gas coming out of a pinhole in one of the seams in the tank.  Crap.  Well that put a stop to my evening.  Pulled the tank and drained the gas out.  Ordered some Caswell tank sealer. 

So while I wait for that to arrive, is there a proper process for starting a bike up after a rebuild?  Any tricks I'm not aware of? 

[calj737]

Aside from what you've done in terms of getting the oil circulating, I'd also spray some oil directly into the cylinders to insure they're fully lubed up.

The lack of spark has nothing to do with the rebuild other than some wire or switch has obviously not returned to working order. Check with a multimeter that you've got voltage at the coils, at the ignition switch, the the Run/Stop switch is functioning, etc. I hate electrical... I've spent the past week re-wiring my bike. What a fcking PITA! But it's been educational to say the least. And TwoTired has been very gracious tormenting me-

[spdygnzlz]

Yep, looks like wiring to the Hondaman unit is working and then out to coils.  Pulled the ignition wire and plug, grounded it and checked for spark.  It's there.  Not huge, but it's there.  Am I supposed to prime the carbs somehow?  Or does it simply take a little bit of cranking before enough fuel is drawn through the system so it can start? 

[spdygnzlz]

So I fixed the tank leak with Caswell's epoxy system and let it cure for a few days before putting gas in.  One thing I've noticed when turning it over though is that the exhaust is sucking in air...that can't be right...right?

[spdygnzlz]

It lives!  Figured it out as a cam position and ignition issue.  Couldn't quite wrap my head around the fact that the 650 crank's notch for TDC is 180 deg from the 550's so I had the cam off and way out of position.  Pulled the top rocker cover and checked #1 piston to make sure it was at TDC by pulling the plug from #1 and doing a visual.  Rotated the cam to the right position and bolted it back up.  Turned the crank another full revolution to make sure that #4 was the same with valves closed.  Lined right up.  After all that it still backfired and had some flames coming out the exhaust.  Then noticed that the wires to the coils were backwards.  Reversed them and pushed the button.  Fired right up.  Idle is a bit high but that's a battle for another day.  Just glad it's running finally! 

Next part is figuring out why the idle is so high and also why it's bogging when i rotate the throttle too quickly.  I should probably dig up the current jet/needle info from dynoman.  Can't wait to get it on the road! 

[streak09]

I am in LOVE with that color. My plan has been to do that gunmetal paint wuth brown seat from the get go, and you have just convinced me.

Very nice work.

[Jeepijee]

  I like the bike too, all come's out gr8 !

[spdygnzlz]

Thanks!  It took a while to figure out the color but settled on Nara Bronze when I saw a Rangerover parked next to my workshop and a CX500 on Bikeexif with similar colors. I'm still hoping to get the grips done in leather to match the seat...  Just glad to know it's actually running.  Still holding my breath for the inevitable oil leak and tweaking that will be required but as least I know the engine works.  I already know I need to source some new oil seals for the oil pump...

[spdygnzlz]

So bike is running ok but after working on it with a local mechanic friend, we think it's running a little lean.  Is there a tuning guide for the Keihin CR's or is there anyone in the Bay Area that has these things down?

[calj737]

Check out FunJimmy's Interceptor build. Latest pages have tuning data from his recent dyno runs.

Here's another: http://forums.sohc4.net/index.php?topic=123033.175

[spdygnzlz]

Ok, its been a while since I've updated this thread.  I just didn't have time to learn to tune the carbs so I brought the bike to a local shop I've worked with in the past.  They got a good chuckle when they saw the bike but were really happy I had the CR's on which made their work pretty easy.  They did their magic and told me the jetting was fine.  They got the idle down and synched the carbs and adjusted the clip on the needles.  When I got the call to pick it up, the mechanic was really impressed with how the bike ran.  He'd never seen a 650/550 motor put together but loving how quick the bike is.  His only complaint is that the suspension needs work.  It's way too stiff, something I've been reserving judgment on while the shocks break in.  Suppose I should call the folks at Works Suspension to get their suggestions on what to do.  For now though, I'm loving riding it.  It's quick and l love how it looks now, and no, it's not a Triumph.

[spdygnzlz]

Follow up on this thread.  Bike's was great for a while until I rode it to work the other day and noticed it was expelling prodigious amount of oil out the breather and onto the ground.  At the moment, my workshop is way too busy and full and I have no time to pull it apart so the bike is parked for the next few months until the dust settles.  Lots of things on the list anyway like cleaning up the wiring, new rear shocks, new springs for R6 fork, new steering stopper (broke it), fixing the tank (dropped it), maybe adding a steering damper, and adding a fuel gauge.  It's a project after all.