Topic: CB 500 Four (1972?) Full Restoration

[MickB]

DH Smarter than the average bear, they're only tiny springs.

[MickB]

Finished the carbs this arvo.
Hopefully on the bike tomorrow.

More carb pictures









Can someone advise me how tight the nuts are where the 2 little flat springs (are between 1&2 and 3&4) go into the holder then attach into the carby stay plate?

[bryanj]

Don't forget to attach fuel pipes whilst carbs on bench , its a swine when they are fitted

[MickB]

Thanks Bryan, I've just worked that out tonight, just pulled 3&4 off to fit the hose.

[MickB]

Just bought SS 3mm screws to replace the rubbish screws on the choke flaps and the throttle valves.

[bryanj]

Careful what and how you fit to choke flap as anything that unscrews will destroy the engine

[MickB]

Thanks Bryan I'll use a little locktite on the screws. They were tight anyway but the locktite will make it more secure

[Restoration Fan]

Just bought SS 3mm screws to replace the rubbish screws on the choke flaps and the throttle valves.

Did you buy those at a store or as part of a kit?
I'm about to purchase the same thing.

[MickB]

Resto Fan I bought them at at at place called Boltmaster in Sydney, they've had every nut and bolt I needed.

[MickB]

Anybody notice the deliberate mistake, the carby drains are all pointed inwards! Doh!

[MickB]

Finished installing fuel lines on the carbs today (after having to take them off the support plate) then bench synced the carbs. Bryanj I doubled checked the choke screws all nice and tight



Carbs are connected to the engine, thanks SohRon for your thread it was made easier.



Installed the new oil pump pressure switch



New rear brake shoes were meant to be fitted today after the carbs, but it always takes longer when you've never done it before.



Can anyone assist? What is this from because I can't remember?

[Restoration Fan]

Mick,
Just reread your thread from start to finish.  Amazing work, man.  You're getting close now!

Ron

[MickB]

Thanks Ron, a lot of help from Calj, Bryanj, DH and many with advise and what to watch out for.
Others who have been encouraging, and also, all the blokes that published on tips and tricks.
I've made plenty of mistakes, some of the build is not as I would have liked due to lack of funds. I would have liked to have fully rebuilt the engine but the cost was prohibitive.
And I've got to make it run yet!

[Valhad]

At a guess, that looks like it might be part of the electrical plate? The bit the blinker relay rubber mounts on?

[MickB]

Valhad I think it must come from another bike as the electrical support plate already has the blinker support.

I'm going to install the air filter next and have a question.

The tube that connects to the bottom of the filter box has a small piece of sponge in the large end of the tube, does it remain or should it be pulled out?

The schematic shows a hollow tube at the wide end.



Part number is correct.



Note the sponge in the wide end.









I've got to get a new piece of wire gauze as this one's rusted.

[DH]

Mick, Not 100% sure, but I think the "sponge" in the end of the tube is a filter to keep out dirt / water.
maybe someone else will add here.....If the metal screen is still in one piece, and still strong and resilient, try soaking it in white vinegar for a while, and take any necessary steps afterwards to stop flash rust. Lookin good Sir

[MickB]

Thanks DH for comment and advise regarding the rust.

However regarding this tube.

SohRon quotes:-

The two final parts that finish up the installation are the drain hoses for the filter/element case and the plenum. They come in two sizes, and while they may look similar, they're actually quite different

The longer hose is the plenum drain hose. It is has an internal foam filter

Foam filter. Remove this when using hose for drain on the filter/element case

Its primary purpose is to drain any gas that might somehow escape the carbs and splash into the plenum. The foam acts as a kind of barrier that lets gas out but doesn't let in a lot of air or debris, so that the correct pressures are maintained inside the plenum during engine operation. It connects to the plenum via this outlet formed into the plenum body where it's secured by an omega clip

[/

This photo is of the Plennum (left) and Air Filter Housing (right).
... the plenum hose can still be had and, with a couple of mods, will work fine. Just cut it to length and remove the internal foam filter mentioned previously.....

I'm confused, do I leave the sponge in or remove it?! Does it drain or keep stuff out of the air filter housing

It finally dawns on me, the 500 doesn't have a Plennum drain, so there's no tube needed, therefore the sponge comes out as it's going into the filter housing; per SohRon's comment ... Foam filter. Remove this when using hose for drain on the filter/element case.

Problem solved unless anyone else disputes my finding.

[DH]

Thanks DH for comment and advise regarding the rust.

However regarding this tube.

SohRon quotes:-

The two final parts that finish up the installation are the drain hoses for the filter/element case and the plenum. They come in two sizes, and while they may look similar, they're actually quite different

The longer hose is the plenum drain hose. It is has an internal foam filter

Foam filter. Remove this when using hose for drain on the filter/element case

Its primary purpose is to drain any gas that might somehow escape the carbs and splash into the plenum. The foam acts as a kind of barrier that lets gas out but doesn't let in a lot of air or debris, so that the correct pressures are maintained inside the plenum during engine operation. It connects to the plenum via this outlet formed into the plenum body where it's secured by an omega clip

[/

This photo is of the Plennum (left) and Air Filter Housing (right).
... the plenum hose can still be had and, with a couple of mods, will work fine. Just cut it to length and remove the internal foam filter mentioned previously.....

I'm confused, do I leave the sponge in or remove it?! Does it drain or keep stuff out of the air filter housing

It finally dawns on me, the 500 doesn't have a Plennum drain, so there's no tube needed, therefore the sponge comes out as it's going into the filter housing; per SohRon's comment ... Foam filter. Remove this when using hose for drain on the filter/element case.

Problem solved unless anyone else disputes my finding.

Sounds plausible to me Either way I'd think you can't go horribly wrong. I'd go with Ron's method as well.

[MickB]

Can someone advise where I can get replica electrical connector blocks to suit the electric plate.
Thanks in advance.

[bryanj]

Those are not easy as the round pin ones were only fitted for about the first 6 months, if its the sub loom on the electrical plate you could try Western Hills Honda for the early part, they also sometimes come up on ebay

[MickB]

Well now I see the drain tube is on the Plennum after thinking it was on the body, all I have at the base of the air filter is a small hole.

[MickB]

Thanks Cal

[MickB]

Air filter on thanks to SohRon for his little how to install the air filter box in one easy lesson.
Waiting on part #10 listed on  the air filter schematic, I got the last one in Australia.

[MickB]

Moving along - installed new rear brake shoes, new coils and drilled handlebars for wiring.

Handlebars with clutch and handbrake.









Installed throttle cables



Is the spring installed correctly as the throttle doesn't snap shut.

[MickB]

Thanks Cal, but I realized I've forgotten to put the spring with the plastic cover on that goes in between carby 2 & 3.
No raw aluminum, it's  there to clamp the handlebar in place, I have 2 of the clamps, the other one is being painted.