Topic: CB550K 1977 - rehab/build thread

[dave500]

seeing the wheels are off id pull the swingarm and clean all the old decaying grease out of it?

[Stev-o]

Looks like a nice buy.  I hope you installed new tubes?

[billingstitan]

Yes - new tubes and rim strips.

@dave: I will look into that - I've never messed with the swingarm - I check for play, and then if they're solid I just pump 'em full of grease.

 I will do some searching on the forum though - I'm definitely all for doing whatever you can while you have them in pieces.

[goldarrow]

Yes - new tubes and rim strips.

@dave: I will look into that - I've never messed with the swingarm - I check for play, and then if they're solid I just pump 'em full of grease.

 I will do some searching on the forum though - I'm definitely all for doing whatever you can while you have them in pieces.

While you're at it.  Consider swingarm bushings, lower shocks mount bushings

[billingstitan]

Didn't get enough 'before' pics - but dammit, I'm not as neat and orderly as some of you guys -

Made some progress friday night - got the defective shinko of the front rim and packed and ready to return. New tire should be here tuesday, along with some other goodies like fork seals.

Rear bearings changed, and cleaned out the left crankcase/sprocket cover. What a mess - I will be high for days from the brake and carb cleaner 

Also did quite a bit of clean up on the swingarm/centerstand, etc. while the wheel was off - was very happy I got a brass wire wheel for my grinder - made cleaning up those sprockets a breeze.

[billingstitan]

Never understood all the issue with changing the rear bearings on these bikes ... until Fri. night. The 'ol pin wrench did not even budge - soaked it with PB blaster - cursed, prayed ... finally resorted to brute force with a sledge and drift - and poof, it broke free and came right off.

Probably not the wisest course - I was expecting a high possibility of screwing it up - but broke free and onward and upward.

[billingstitan]

Bearings popped right out from both wheels - not in bad shape either. Always a good feeling to have new sealed ones in place though. Plus, there was a lot of clean up that needed to be done on the wheels. Just waiting on some rear brakes and a front caliper and the wheels/brakes will be done!

[billingstitan]

More grunge - took lots of PB and elbow grease to get these clean, followed by vision-inducing amount of brake cleaner to ensure everything was dry 

[billingstitan]

ALL-BALL's of course - I'd prob buy them even if they were sh***y bearings, just because I can go around saying I've got a set of ALL-BALL's on my Honda 

[billingstitan]

Just need a set of rear drums, hopefully on the way sometime this year from DSS, and the rear wheel's ready to go!

After that, pulled of the sprocket cover and spent an hour or so making that squeaky clean, then reinstalled with some stainless steel bolts in place of the OEM phillip's head screws (used anti-seize).

Also scrubbed and sprayed and went through a gallon of carb/brake/engine cleaner getting the swingarm/rear engine/center/kickstand cleaned up. They did a dandy job hosing the bike off - but once you get down into it, there was a LOT of grunge and build up.

Got a fitting on the swingarm zurk and pumped as much red grease in there as it could hold. Not quite up for pulling the swingarm yet - too much summer left - I'll save that for when it snows. Eat the elephant one bite at a time 

That's alright though - this is going to be a pretty bike when it's all done.

 

[billingstitan]

Got most of my wiring done tonight - headlight works, blinkers are installed on the fork ears I ordered - doesn't seem like my gauge lights or horn work, but I am close enough for now -

Still need to figure out where to hook those green wires from the mounting nuts on the headlight can --- seems they must go to the group of green wires with the two female receptacles that are at the center-top of the photo.

Couldn't find a definitive answer in the wiring diagram ... but I may be tired.

In any case - lights works, etc. - fork seals will be here tomorrow, so I should be able to have this pony ready to at least test ride a bit this week. Got some more parts on order - but I would like to get 100 miles on it before July.

[dave500]

in the bucket just go colour to colour,watch for subtle stripes.

[billingstitan]

Thanks, Dave500 - been doing a lot of searching on this and other issues - your knowledge has been incredibly helpful.

Sooo - got the wires cobbled together - got a great deal on a complete headlight assembly on ebay - had some dings, so I scuffed it up a bit and sprayed it before getting the rat's next of wires packed into the headlamp.

Pulled the forks, cleaned and replaced the seals last night -so a good opportunity to finish up the wiring.

[billingstitan]

Funny how you forget things ... disassembled my forks then went to work on the allen bolt at the base of forks, where the axle rides ... hmmm, why is this just spinning?

Oh yeah - don't take out the springs until you've taken out that bolt. Only took 20 minutes to pull that from the recesses of my brain.

Forks were in remarkably good condition - relatively clean inside - no water that I could detect - not much oil either.

Got the forks back on, along with the new/used headlight can -- the darn fork ears are about a half-inch too short, so there's some movement - I used some rubber washers beneath, and after I tightened it down it seems to help, although I will have to ponder a more permanent solution.

[billingstitan]

Wiring was a mess, what with it being spliced, diced and taped together to fit a Kawasaki fairing. Got everything going - except the tailight only worked when it was on the "Park" position.

Traced wires for about half and hour - cleaned terminals, studied wiring diagram (a little tough, as PO used non-standard colors for splices) - finally gave up and went to bed (posting on the forum for advice).

Then, as I'm drifting off to sleep - it hits me - the instrument lights don't work either  Seems like I remember in a car, when your tail light goes out, so do your instrument lights.

Oh f*** me - I didn't even check the FUSE!!

So, off downstairs I crept in my PJs and barefeet - and yup, just a blown fuse - doh!!

Horn still doesn't work - I do get straight power to the horn from I believe a black wire - (i.e. circuit tester lights up whether horn button is pressed or not). Couldn't get any power from the horn to the other wire whether the horn was depressed or not - not too worried. Will troubleshoot later - may just be the horn itself. Want to get a few hundred miles on this bike before I spent too much time or money.

Only other oddity were the turn signals - found the correct wiring for those - blue & blue/white on one side and orange, orange/white on the other. Plugged them in, but then the right side acted like a running light as soon as the key was switched on (still blinked tho).

So, unplugged that - fixed the problem; and poof, the left side does the same thing. Disconnected one of the wires there, and now they seem to work fine. I assume the single source of power is fine, and the connection to the bike is providing the ground. Will have to troubleshoot that one a bit more as well.

Buuuut - when it was all said and done I've got all lights - high/low beam, instruments, tail, brake and blinkers - seems to be good to go! Probably do some additional troubleshooting on that horn and those blinkers, but hey, it works, doesn't seem to be shorting anywhere, so want to get it on the road for some break in miles.

[billingstitan]

Next step was to get the new bearings on the front wheel, and get everything reassembled on that front. Again, not bad as far as corrosion - had definitely been sitting for awhile, but no serious rust. The axle nut was holy hell to remove initially, but used a brass wheel to clean that up and coated it in grease and let it sit wrapped in a papertowel for a few days.

Pretty clean - bearings went in slick - overnight in the freezer, then a little judicious use of a heat gun, a 30mm socket and a 6 lb sledge, and they popped right in.

Brilliant mechanic that I am - I immediately tried to put the brake disc on backwards - "why are these bolts too short?" That only took a second to sort out though 

[billingstitan]

Got some parts from David Silver Spares enroute, but of course since they're the last pieces I need to put the wheels together ... UPS got delayed due to a "late trailer" and instead of yesterday, they aren't going to arrive until next week.

Still - I got a start on the front brake. It was locked pretty tight when I picked up the bike ... now I see why.

Despite the grime - it's in pretty good shape - no pits or otherwise. Already ran about a half-bottle of DOT3 through the lines, but there's still a lot of particulate.

[billingstitan]

This stuff is straight-up 'sludge' had an almost gel-like consistency. Pulled it apart and brake-cleanered the living s**t out of the whole thing. Took a bit of elbow grease - everything came out pretty clean. Mounted the other pad - always use a ton of the Dow-Corning grease (on everything but the pad surface of course) - and that seems to help a lot with the chronic CB550 squeal.

[billingstitan]

Wrapped up the front end by mounting the fender and caliper mount, then bolted up the tire. Hey - this thing is starting to look like a bike!

[billingstitan]

Finished up the night by adjusting the valves - will check timing and synch the carbs this weekend, and continue to plug away at the grime. Rest of the parts should be in next week - hopefully will have it on the road for an initial run in a few more days.

[dave500]

good job!yeah the bucket is a birds nest theres no other way,keep taking your time and enjoying it and itll provide lots of satisfaction when your riding it.

[Stev-o]

Startin to look like a nice bike!

[billingstitan]

Hmmm ... timing was a bit off tonight. Synched the carbs first - ass-backwards, I know - but I was seeing some arcing coming from the points- even off the plate itself, which I do not recall as being normal. Think I will replace these points and condensers with a spare set from my old engine. See if that makes a difference.

Carbs synched a little odd - #3 was WAY off, and took some pretty radical adjustment to bring them all in line - but perhaps that has to do with the timing. It was a short night - I'm going to hit the points first thing tomorrow and then recheck the synch and then sit with my thumb up my a** waiting for the rest of the parts to arrive 

[Stev-o]

Why aren't you installing new points/condensers?

[billingstitan]

Unfortunately, I've got about $2,300 reasons, stev-o  ... just dropped $700 on a new engine for the other CB550; then $1275 for this 'un, as well as the assorted madness (does it ever stop?!?) for parts that goes along with rehabbing one, AND I just dropped the seat off at the upholterer's because I just couldn't take it for it's virgin first ride with that crotchety 'ol Corbin two-up saddle on it 

Just tight on funds at this 'point' - I wasn't really planning on getting this bike, but ... well ... I just couldn't pass it up ... sure you know how THAT goes 

In any case, my spare engine had relatively new TEK points and condensers so for the time being I'm going with those just to get this running and on the road. Unless there's a good source I don't know about, last time I checked a fresh set of TEK points & condensers runs about $110? Ouch.

In other news ... I noticed number 2 seems to struggle a bit to fire - although once you let it warm up and get some revs going it seems to fire just fine. Cleaned then swapped plugs w/ number one - again, doesn't NOT fire, but you tell it's not hitting right on every one until it gets warmed up.

Anyway ... it may not be the best approach - but after I get the oil changed, oil pan cleaned, and the big safety type items out of the way (brakes, wheel bearings, etc.) I really like to run a bike that has been sitting for a decade-plus like this for several hundred miles before I go too crazy w/ diagnosing, buying replacement stuff. Seems like you always get some of the "kinks" out (and often find other kinks).

But truth be told - my bike funds are edging over into the red, so I'm kinda working with what I got as much as possible (although everytime I say I'm not buying another GD part - I pretty much end up buying another part, lol)