Topic: CB550 Cafe project

[nbcam]

Decided it was finally time to start a project trend, this is my first trend so take it easy  spent weeks looking on craigslist and eventually bought this bike about two months from a local guy here in Boston, he did not have the bike running for about 3 years. I've grown up around bikes and cars so I have always wanted to build myself a cafe racer. Here is the condition of the bike when I bought it, it was in good condition overall.



Before I started any work on the bike  I wanted to get the bike running so I done  the 3000 mile tune up, disassembled the carbs and cleaned them using carb cleaner, carbs were not too dirty so I kept all the OEM brass and just replaced the o-rings and seals. Set the float height on the carbs before I put them back on the bike.

Carb Jets:
Main Jet #98
Slow Jet #38
Float Height 22mm




Changed the Oil and filter, Spark plugs and Changed the points as they were well worn. Also set the ignition timing and valve clearance on the bike. Tested each spark plug for a spark off the frame and noticed that i had no spark on cylinder 2, broke out the multi-meter and tested the coils, all looked good so I narrowed it down to a bad spark plug cap.

Points Gap:
Standard point gap = 0.012in - 0.016in or 0.3 - 0.4mm
Spark Plug Gap:
0.02 to 0.03in or 0.6 to 0.7mm
Valve Tappet Clearance:
Inlet = 0.002in / 0.05mm
Exhaust = 0.003in / 0.08mm







Got 4 new spark plug caps and put them on the bike and had a spark on all 4 cylinders, I then gave the tank a quick clean and put the carbs back on the bike and reassembled the air box. Charged up the battery and hoped for the best !!!

Put the battery in and went to start the bike, I was surprised how easily the bike started  and sounded pretty good too. Everything looked good no major leaks or issues, with that being said i only had the bike running for about five mins !!

 I wanted to have the bike running before I start any work. Next step is to strip the bike down and decide on seat options etc. Sorry for the lack of pictures I will get more uploaded shortly

[calj737]

Your links ar dead with Photobucket 

[SOHC4 Cafe Racer Fan]

Cursed Photobucket strikes again!

[nbcam]

sorry guys only noticed this now, ill see if i can change the settings on photo bucket, not that familiar with photo bucket that this was the easiest way to upload pictures

[nbcam]

Being slacking big time on this trend, had a crazy few weeks at work, good news is I've still managed some time to work on the bike. Finally got a work around with the pictures

Bike when I bought it:




Carbs were not too dirty but I ended up disassembling them and soaking them in carb cleaner from auto zone and replaces all seal.


Had issues with no spark, set the timing and checked coil resistance, all looked normal ended up being a bad spark plug cap !!!




I then got stuck into striping the bike down and began the process of bagging and tagging everything, the end result !!

After some advice from site members (cannot remember your name, my bad ) I striped the paint off the tank and frame using aviation paint removal gel, worked a treat !!

Quick wire brush and the end result



Quick sand and polish of the tank, hard to see very bad picture and poor basement lighting





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[nbcam]

Currently the tank and frame is at a local custom shop, getting a hand made seat installed, going for the round open back style seat

Pictures don't do it justice but I like the style and fits well with no frame modifications




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[SOHC4 Cafe Racer Fan]

That's a nice piece.  Can you provide more details? Who made it?

[nbcam]

That's a nice piece.  Can you provide more details? Who made it?

The seat is made by cafe cycles in RI, the guy has a shop there and mainly builds cafe racers, had some nice bikes around the shop when I went to visit, seen a video of one of his bikes on YouTube and really liked his seats

I'm sure he won't mind but these are some of the bikes he has got on his Facebook page

 



I seen the GT 380 in his shop when I went to visit very nice looking bike up close


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[SOHC4 Cafe Racer Fan]

I assume that seat is aluminum.  Are you relocating your electronics or keeping the side covers?

[nbcam]

yes the seat is aluminum, TIG welded on both sides and smoothed to a mirror finish. Yes my plan is to relocate the electronics, I will see when I get the seat and frame back if there is enough place under the cowl for the battery and electronics. I plan to install a slim battery and M-Unit on the bike. If there is not enough place I will go with a small tray under the seat 

[Stev-o]

+1 that seat looks nice.

The GT380 looks great too, but would've like to see some high performance tires on it rather than Firestone tractor tires!

[nbcam]

+1 that seat looks nice.

The GT380 looks great too, but would've like to see some high performance tires on it rather than Firestone tractor tires!

Yeah I'm looking forward to see how it looks on the frame

You will be glad to hear, he posted he had new tires ordered so the Firestone tractor tires might be going


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[nbcam]

While the frame and tank are at the shop I have decided to complete some of the easier tasks

I striped the front and back brakes. Back brakes look in good shape might just replace the springs



Plan to replace both front disk / rotor and pads, both are in poor shape





The brake cylinder piston and seal will be changed also, the piston looks fine do you usually need to replace both or could I get away with changing the seal ??





Learned the hard trying to remove the brake pads as it was near impossible, had to reconnect the master cylinder bleed the brake and push the piston out that way.


Any suggestions on what type of brake disk / rotor, pads and piston rebuild kit to buy ??





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[Stev-o]

Piston appears to be fine unless there is pitting that can be felt with your fingernail. Or get a phenolic one [link below].
Def order a new seal, clean clean clean the inside of that caliper, especially the groove. And paint or polish.

The rotor could be sent to Godffrey for thinning and drilling [lighter weight] and I like EBC pads.

http://www.vinmoto.org/gallery/v/VinMoto-Garage/album03/Godfferys-Garage-123/Parts+and+service/

[nbcam]

Piston appears to be fine unless there is pitting that can be felt with your fingernail. Or get a phenolic one [link below].
Def order a new seal, clean clean clean the inside of that caliper, especially the groove. And paint or polish.

The rotor could be sent to Godffrey for thinning and drilling [lighter weight] and I like EBC pads.

http://www.vinmoto.org/gallery/v/VinMoto-Garage/album03/Godfferys-Garage-123/Parts+and+service/

Think I will get away with just replacing the seal, I will put the brake calipers in the ultrasonic cleaner ? 

Do you guys think this is a good or bad idea, once the seal is out, can I do any damage to the caliper ??

Plan to use the Godffrey thinned and drilled brake disk thanks for the link

Orders a few new parts today:

•Brake calipers seal
•Front pads
•Master cylinder rebuild kit
•Rear shoe springs
•Front fork seal and dust caps

Plan to spend the weekend cleaning and getting the calipers and forks ready for the new parts


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[nbcam]

Got pictures from the shop today, they started to mount the seat today, this is it just mocked up, looking forward to see what it looks like with upholstery on it, let me know what you think all feedback appreciated




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[nbcam]

Slowly getting back at this bike, got the fork seals replaced and painted them gold

Plan to send the front rotor to Godffery and get a thinned and drilled disk for the front


Going to tackle the front wheel bearings next

 


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[Chris_Stiles]

HEY good call on Pete, everything he makes is really nice, I just ordered a type 5 seat from him and am waiting to see leather samples.

[nbcam]

thanks  Pete is a top guy to deal with, I am very happy how the seat turned out, got him to fit it also he done a good job and would highly recommend him.

[nbcam]

Have being working on the bike the past few nights, decided I would change the swing arm bushings. Little bit of a struggle to remove the old bushings, ended up using allot of heat and a drift along with an internal bearing puller


Used a hone to clean up the insides of the swing arm



Got the replacement bushings from kenosha_kid on eBay, I know they are not as good as the sets Hondaman makes but I could only afford these for now.

Heat up the swing arm and used a threaded bar to press the bushing back in



Pretty sure I know the answer to this bit the swing arm collar has some wear on it, should I replace this and if so can these be bought original or any good replacements out there ?? Below is a pic of the wear on the swing arm collar

 


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[Mike Something]

What paint did you use for the fork? I wanted to do a GSXR swap and love the gold, this might due until I find a good deal on a new fork!

[nbcam]

Hey,

I wanted to do a GSXR fork swap also but did not have the funds so sprayed these with Rust-Oleum Metallic Gold, paint and primer in one and then a few coats of clear coat.

[Marissa]

NBcam,

If that's the only worn section, I would measure it with a caliper or micrometer and check to see how worn in it is. If the difference between that and the inner diameter of the swingarm bushings is too much, you should replace it. I forget what the specs are exactly but I think Hondaman has some specs listed on my thread if you'd like to check it out.

Nice project so far!

[bill440cars]

      I am liking this 550 build. I actually started on one myself, Life happened and I never got back to it. Maybe this time, after I take care of a few things, I can actually get back on mine. And I also like your treatment on the forks. Your attention to detail, says a lot too. 

[Hasenkopf]

yeah, and bonus points if you don't butcher the frame