Topic: CB 500 Four (1972?) Full Restoration

[bryanj]

If you are VERY good with a mic and have one with rounded anvils you can measure the shell thickness, preferably where not worn near the join, and sort out the ones that are the same.

Problem is you have to be accurate to 1/1000 of a mm which is basically sod all

[dave500]

don't tell anyone that I said it but if you put all the old shells back in itll be ok,they wernt worn out,just scuff the rod ends and caps on 600 wet and dry and glass and close em up,itll be fine,these bottom ends are built way overkill and aren't really that precise!they were considered in the day though.

don't mix the rods and caps though!!ever!!

[MickB]

Dave thanks for reply, no I didn't mix them up they were in a re sealable  plastic bag (remember when I bought the bike, it came in pieces). I'll get them out and clean them and put some photos on, get plastiguage and give it a go.

[MickB]

Dave thanks for reply, no I didn't mix them up they were in a re sealable  plastic bag (remember when I bought the bike, it came in pieces). I'll get them out and clean them and put some photos on, get plastiguage and give it a go.

[MickB]

Dave probably hard to tell from a photo but here are the bearings with some close ups.

To me some look like they've never been used, but I don't really know.









What do you think?

[dave500]

the surface of this type of bearing is actually designed to let foreign debris embed into it!i cant really tell without seeing those in person but if the motor was running fine itll all be ok so long as each shell goes back to where it came from,ive done plenty of these engines and re run all the shells,ive also bought new shells as a matter of course in other motors,i always linish the crank journals with the old 600 wet/dry and shoe string trick like trying to start a fire?wrap enough paper around the journal to overlap then wind a boot lace around and around leaving two long ends to zig zag the paper around back and forth,soaked in kero or engine oil,be sure to wash everything like new.i don't have a photo of a crank being done but this should give you the idea,just spin it around a dozen times to sort of deglaze the journal.

[MickB]

Thanks again Dave, the tip on the 600 wet and dry is of great help. The crank has been checked over (by Heads Plus)) and the journals are right in spec ( size is shown in the photo).



Unfortunately the bearing shells were all loose in a bag (I have no idea which she'll goes with which journal).

I'll have Ivan (best mechanic in Sydney) have a look at them.

[dave500]

if they are mixed up replace them,or try and sort them out by wear marks(youll get two or three correct?)get that water of that journal right now!

[MickB]

Thanks Dave, the water was there 8 months ago and was dealt with then, I was hosing all the crud off the parts and then dried and oiled.

I think new bearing shells are the order of the day, off to David Silver's.

On another note after cleaning and prep work I got a lot of painting of parts done today, pegs, battery frame, seat, ignition surround, engine mounts and others parts.

Seat before paint





Lacquered 2 coats front and rear hubs with POR Glisten.

Felt like I really make some progress today

[dave500]

I number with a sharpie(or a skin head?)bearing shells on the back cylinder # and upper or lower,theyll allways re run ok unless there was a problem before hand you knew about?,they should be floating on a cushion of hot oil?plain bearings don't touch the crank when running more or less,roller type cranks that run low splash pressure or two strokes have an actual physical contact type bearing.

[MickB]

Thanks Dave you've been a real help

Regards

Mick

[bryanj]

Ones that look like the 2nd individual pic down are too dirty and marked to use, top pic AOK

With a used crank,rods and cases its fine to fit a full set of the tightest tolerance you can find (black was it when all were available) then just run it in properly for 2-3 000 with a couple of oil changes.

honda's original idea was to build them as if they had been run in so all the motor needed was a short bedding in period.

Kawasaki caught a cold when people ran in the first Z1000 too much and they ended up reboring under warantee as the bores glazed meaning high oil consumption--should just have said keep it below the speed limit (70mph in UK) till you hit 4th gear!!!

[MickB]

Thanks Bryan but I'm not sure some are ice and shiney. I'm going to get a mechanic mate to advise me, he's been a Mercedes mechanic for 30+ years.

Today got a fair bit done  -

Painted:-

2nd top coat on a stack of bits

From this



And this



To this



And this



1st coat on top triple tree, tachometer mount and idiot dash

2 hours on stripping tank - no dints under paint - you flaming beauty!



More tomorrow.

[dave500]

you can reuse those old shells,those discoloured marks wont matter,they aint gouged/scored or otherwise ruined,or just replace them all,thats what your benz man will say anyway?if I was pulling the 308 out of my HQ I rebuilt in about 92 id be replacing the shells though!good work on that seat base and tank.

[MickB]

Ok Dave, I'll number each bearing shell and photo each and send to you and give me your advice. I have no experience with bearings.

It'll save a stack of dough, David Silver wants around $150.

[MickB]

My painted wind chime

[dave500]

modern art?

[Stev-o]

modern art?

I'd buy that.  How much?

[MickB]

I was too quick to jump, I thought I was going well stripping the tank. I thought there were no dints, I've now found about 4 - 5 small dints and 1 large dint complete with 3 small holes filled with bog!

[calj737]

Looks like some nutty Aussie slammed his beer can down after a ride? Have someone about who can repair the dents and holes? it shouldn't be too difficult to have those pushed out and then welded up properly.

[MickB]

Cal great minds think alike.

[rtbmrgl]

I was too quick to jump, I thought I was going well stripping the tank. I thought there were no dints, I've now found about 4 - 5 small dints and 1 large dint complete with 3 small holes filled with bog!

I discovered the same thing on my tank, knock the bondo out, drilled a hole and popped the dent out then brazed the hole.
My new neighbor was a little concerned when they found out I was going to weld on a gas tank.
Told him not to worry, I planned on welding the tank between our driveway so i didn't blow up my garage, heck don't want to damage my new tool box.

[MickB]

Some just don't understand priorities.

[MickB]

Tank is at metal fabricators bronzing the holes and he says he can get all the dints out - wait and see.

Tonight I just finished laceing front and back wheels, another step forward.

Pulled oil pumps apart, next clean them and reassemble.

Feeling motivated, bought a helmet so I can ride my daughter's Kwaka ZZR250.

Photos tomorrow. Now bedtime

[calj737]

Btw- it's in the post from last week. Look for it early next week in the letterbox.

Hope your fabricator doesn't fill the dings with lead and instead pulls them out...