Topic: CB500 rebuild - first bike/project

[paul_D]

This is my first bike and rebuild.

The bike is from europe, not sure for which market.
The frame isnt stamped for year.
cb500-2057419
cb500E-2145923

649A carbs.


Here is what I'm working with and a little of what I have on hand.

[paul_D]

Over the winter, Ive done a little work since the purchase last summer.

The carbs have been thoroughly cleaned, passages chased and o-rings changed.

[paul_D]

The seat was stripped and cleaned and repainted.

My father had it redone by his friend (upholsterer), Ive no idea how it'll fit though.

[paul_D]

The engine was dismantled and cleaned.

orings and gaskets changed
valves lapped
primary and cam chain changed.

[paul_D]

Summers project ? Make it run! with the help of these parts on my list.

petcock rebuild.
spark plug caps - NGK SD05F & XD05F
steering bearing kit- AllBalls
Wheel bearing kit- Front and back AllBalls
Front and back break pads - EBC FA13 & 316
spark plugs - NGK D7EA
battery - 12N12A-4A-1
Air filter - Uni Nu-4055
Oil filter and 10W40
Master cylinder rebuild kit (K&L i think)
IRC GS-11 tires 3.25-19 front & 3.50-18 rear with new tubes and rim strips
New honda fork seals
swingarm bushing from kenoshakid

anything else I should look at ?

[Mo]

I wouldn't forget to do a 3000 mile maintenance. Include ignition timing, valve timing/clearance, replace fork oil etc. All detailed in the manual.

I have a CB500 I'm working on too and have run into a ton of problems so feel free to ask if you are unsure! Also, I have the IRC GS11 and I think they are awesome.

RIDE ON 

[paul_D]

Yeah fork rebuild is planned.. going to strip them down and polish the fork tubes and fill the pits so the seals work nicely and smoothly.

The engine has a dyna ignition system which will be fun retiming so it'll run as I had to uninstall it to crack the case and I don't have the manual.  The valves were all lapped and adjusted when I put it back together.

Getting the jets right could be interesting. The bike has a jardine 4-1 and a stock air box with Uni-filter.  I say interesting because the mains where 125's over 100/78 (not sure which (100 or 78) came originally in the 649A's... Not sure the 649A's are even original to the bike).

[paul_D]

Been BUSY since I've moved home for the summer to work ~7days a week.

Here's a quick update.

Every part I thought I would or could need after having stripped the bike to the bare frame has been ordered.
Went for metzeller lasertec 3.25-19 front and 4.00-18 rears instead of the IRC GS-11's. I wanted something I could trust.
I should start receiving my orders next week and by then the bikes frame should be cleaned, sanded, primed and painted so I can start reinstalling parts... Dad wants to reclaim some of the garage I claimed during the tare down.

Oh and build a work platform out of 8 2x3x8's and 1 sheet of 1/2 osb.. its 16" high and 2 foot wide by 8 feet long. Works great

Will have to post some pictures later.

[Tews19]

Nice project! Seat looks great

[paul_D]

Parts are starting to come in from various orders.

I stripped and cleaned the frame uncovering some bare metal under dirt/grease and some more surface rust. Sanded all the rust down and scuffed the whole frame. Going to hit it with some semi-gloss black tremclad after I wipe the whole frame down with a paint prep/degreaser.

[Randy]

Great job so far...I have a 73 500K2.. so if you run into a snag, give a holler..

[brooze72]

Parts are starting to come in from various orders.

I stripped and cleaned the frame uncovering some bare metal under dirt/grease and some more surface rust. Sanded all the rust down and scuffed the whole frame. Going to hit it with some semi-gloss black tremclad after I wipe the whole frame down with a paint prep/degreaser.

Mine is a 72, ask away if any questions or need a link to parts.  Since you're right down to the frame & if you can swing it, you would never regret powder coating, IMO.

[paul_D]

Thanks guys for the offer of help.

Brooze, my wallet would regret it. Doing this build while I am saving to go back to school in the fall for year 3 of mechanical engineering.

[paul_D]

1st - Here is the bike just after I pulled it out of the car and popped a few parts on it to show my Dad.

2nd - And here is the bike in the Gazebo*/Spray booth ready for some paint to clean it up. (scuffed, wiped and degreased).

*(the plywood comes off to reveal all the screening)

[paul_D]

Starting reassembly and started installing some parts I ordered..

Ordered house shape o-rings from Sirius for the carbs

[paul_D]

Ive been busy and have come a long way.  Working alot and not much time has meant ive focused on the bike and not so much on updating this list.

The bike started first try, though it is running rich right now. carbs need some syncing.

I played with the clutch but it either engages and bike starts pulling or the clutch slips while in gear.   Need some help here.

otherwise, fill and bleed brakes. Add a rear taillight bulb. Glue the horn button back on. Fix the horn. Install some mirrors. Double check everything and I should be good to go.

[brooze72]

Yes you have come a long way Paul, congratulations! 

What kind of help do you need with the clutch?  Are you aware of the adjuster on the left sprocket cover?  Have you checked the clutch rod length & for wear?  Proper amount of clutch plates & springs?  Right type of oil?  Sorry for bombarding you, check into this stuff & post some details.

[paul_D]

Clutch is working now, thanks. Took it apart. Looks like the others ive seen on this site. One side of the drum that houses the screw that drive the rod was broken. Spun it 180degrees like one post said.. Greased it all, put it back together and it worked nicely.

Now onto syncing the carbs. I am not the guy for this. I tried a 4 tube with oil DIY manometer, but without restrictors, my oil became full of air bubbles and just wasnt working for me.

When i first started it the other day after the rebuild it had some white smoke.. Now its smoking a little blue :S

[paul_D]

Well, i built a manometer and synced the carbs.

I test road it and it stutters like crazy going into gear and when i get it above about 3000 i loose all power and the exhaust seems to sputter.

I think it is the ignition timing which I am having a hard time identifying so that i can set it.

Plus my exhaust is very sooty and it rubs my frame.