Topic: CB500K1 Cafe to Stock (well more or less!)

[754]

 I like the way your mate crimps the ring.
Good luck and fun riding with the bike.

[AndyH]

That's an ear-to-ear grin for you!

Thanks in no small part to the sub-harness you supplied Cal! 

Waiting (im)patiently for a replacement crimp ring from NL (Lecram @ 750faces.com) to complete my tacho refurb.
I made a "newby" mistake earlier and didn't check before fitting the base of the tacho upside -down!! 

 

[calj737]

Waiting (im)patiently for a replacement crimp ring from NL (Lecram @ 750faces.com) to complete my tacho refurb.
I made a "newby" mistake earlier and didn't check before fitting the base of the tacho upside -down!! 

Well you are in the Southern Hem. Perfectly understandable mistake 

[AndyH]

Waiting (im)patiently for a replacement crimp ring from NL (Lecram @ 750faces.com) to complete my tacho refurb.
I made a "newby" mistake earlier and didn't check before fitting the base of the tacho upside -down!! 

Well you are in the Southern Hem. Perfectly understandable mistake 

    I should've thought of that as an excuse!!

[AndyH]

While setting up a float bowl swap between #1 and #2 carbs to isolate an annoying leak in #2, I took the LHS crankcase cover off to more easily remove the bowls (clutch cable in the way).

Pleasingly, there's no sign of any oil leaks from the various seals, and the clutch push rod is still in one piece! 
I also took the opportunity to give the neutral switch components a clean up, as I was experiencing the odd time when the indicator didn't indicate when in neutral!

Now to wait to see if the overflow leak problem has swapped to #1 carb, stayed on #2 carb or gone away. 

[AndyH]

Well, #2 still leaked.  See my other thread for further details.

[AndyH]

Took the bike for a blat this arvo after tweaking the timing on the Dyna S.  Went like a shower of ****!! 
Waiting now for the paint job on the side covers to be done.  Tappet check/adjust tomorrow and carb sync a bit further down the track.  Even furtherer down the track, new or cad-plated existing spokes and a cleanup of both rims, hubs etc.

[AndyH]

I received the replacement (read "correct") tacho from Bryanj today and checked its operation...all good!
Now in the process of refurbishing before mounting it permanently.
Also did a check of the charging circuit.  Voltage at 3000rpm and above was a bit low so tweaked the regulator voltage adjust screw, now seeing ~14.5v as per shop manual.
Waiting now for the paintjob completion on the side covers.
Also received a carb repair kit from cruzinimage_au.

[calj737]

Also received a carb repair kit from cruzinimage_au.

Don't use the "hard parts" only the O-rings and gaskets. Whenever possible stick with stock jets, needles and float valves.

[AndyH]

Also received a carb repair kit from cruzinimage_au.

Don't use the "hard parts" only the O-rings and gaskets. Whenever possible stick with stock jets, needles and float valves.

That was my plan Cal but it seems the carbs already have non-OEM hard parts, if carb #1 is anything to go by. 

[calj737]

In your signature...

1972 CB500 Four K1 (AUS version)
Previously owned..and thoroughly miskept

FTFY 

[AndyH]

In your signature...

1972 CB500 Four K1 (AUS version)
Previously owned..and thoroughly miskept

FTFY 

So true! 

[AndyH]

My sidecovers should be ready for pickup at the end of this week!
Also have a sync kit on its way.  The leaking carbs (overflow after a day or 3) are still unresolved as #3 dumped today. 
Anyway, I'll sync the carbs and at a later date pull the carbs if the o/flow issue with petcock ON still occurs.

[AndyH]

The carb sync gauges arrived today.  Being relatively cheap I didn't expect "professional" quality and I didn't get it! 
The needles at rest were all in different spots so I figured there must be a way to make them all the same.  The "way" was to ease off the front faces of each gauge and "reset" the needles to the proper spot.  This done, I then set up my trusty old vacuum cleaner to provide a pretty constant vacuum for the 5mm hoses.  Fortunately, all 4 gauges read within a gnat's c0ck of each other!    Unexpected roadblocks notwithstanding, I'll do the sync tomorrow.

Long story short, the original side covers are now being replaced with a set from Joe (www.fb-stuff.com) which I ordered over the w/end here, so hopefully will see them in the next couple of weeks.

[AndyH]

Still wasn't happy with the gauges, so borrowed my mate's Motion Pro Synchroniser to confirm what the gauges were saying.

It was interesting to watch the interaction between the carbs as adjustments were made.  I was able to get all 4 carbs pretty well exactly the same and also confirm that the gauges were close, but not quite as accurate.  I believe this type of comparison has been discussed elsewhere but it's nice to see it in the real world!

I still have this current problem though, if I restart the bike after 15min/30mins/1hr/6hrs etc. it stumbles and farts and sounds like at least one cylinder is not firing properly, if at all  .  It's very hard to get running 1st off.
But once it “clears its throat” it idles quite well and seems to accelerate without coughs or splutters.  Blipping the throttle, it comes back to idle without drama.

This lack of normal start has only occurred since I put some Nulon (Aussie stuff) carb cleaner in the tank, hoping at the time it may have cleared the problem with the overflow on #2 carb.  In fact #3 has started o/flowing as well! 

I have new hoses from the tank to the carbs, but maybe the small hoses that interconnect 1 to 2, and 3 to 4 have reacted to the carb cleaner and particles from them are now clogging the float needle(s) and maybe the slow jets ……either that or crud that has existed in the carbs before “dosing”.   In any case, a complete carb refurb seems to me to be the best approach now.
Sound like a good idea?

Cheers, Andy (aka Himble)

[calj737]

Apologies for not looking back to check, but have you done a Clear Tube fuel level check? You can’t rely on setting the floats by the book, the CT confirms exactly where the fuel is within the bowl.

[AndyH]

Did a CT test 2 or 3 weeks ago Cal.  Carbs 1,3 and 4 were ~2mm below seam, carb 2 was ~6mm.  It was the only one overflowing at the time. 

As carb 3 is now overflowing, I'll do another CT test on all and report back next hour or two  (having breakfast now!).

[calj737]

Not necessary if you’ve done it. Probably some funk in the float seat. Open petcock until bowls fill. If #3 is dripping open drain valve and tap the carb body with a screwdriver handle. Catch the fuel coming out and inspect for smutz. May just dislodge some debris.

[AndyH]

Definitely some crudge hanging around in the carbs.  Drained all 4 and some varnish type bits showing up.
Time to pull the rack and give them a good going over!

[calj737]

You might pause and check your fuel tank thoroughly. And do clean up the petcock too. Make sure the internal fuel filter is in place inside the tank.

[AndyH]

You might pause and check your fuel tank thoroughly. And do clean up the petcock too. Make sure the internal fuel filter is in place inside the tank.

Did that this afternoon Cal.  A very small amount of junk was caught by the filter.  The varnish bits found in draining the carbs would not have passed thru the petcock filter.

[AndyH]

OK, carbs have been removed, de-racked, disassembled, cleaned, refurbished, reassembled, re-racked and now on the bench for some checks before returning to the bike.
All is good….so far!

[AndyH]

Carb sync....almost there!

[AndyH]

Bike is running nicely now, and today I received the side covers from Joe! 
Once they're painted and the emblems fitted, that will be "practical completion". 

Season #2 will commence after "Down Under" Summer! 

[AndyH]

Side covers in with the painter today.  Should get them back at the end of the week.

This is how the bike looks now, sans side covers.