Topic: short 550 rebuild thread - facelift

[Shtonecb500]

right hand side cover showed up broken, there was no protective wrap or anything in the box and the plastic is a harder plastic than I would like.
I initiated a return, for some reason I need to wait until 14th if the person doesnt respond and then ebay will get involved...seems like bull#$%*.

I wouldn't buy these if you are looking for reproduction covers, I guess the black ones from 4into1 are the better buy even though they cost 110 bucks.

I believe that 4into1 sells covers made by Low Pressure Mouldings.  These are very good quality and very stout.

yeah those are about 120 bucks, franks side covers are around 80 a pair and its damn near impossible to find a solo used right hand side cover on marketplaces..there is one on ebay right now for 55 shipped, you can buy a solo RH side from 4into1 for 58 shipped, but they dont come predrilled and if I were to get one it wouldn't match the stock left one - which kinda bothers me...i know, it shouldn't matter.

[Shtonecb500]

I wont be doing any aggressive riding on this bike anymore and have decided to change a few things about it. The entire front end is coming off and the only fancy thing about it is going to be polished fork lowers, the front dual disc wheel, tarozzi brace and fender, I might even ditch the speedo delete to make my life easier up top with instruments. That means the billet triple tree, LSL fork ears, TNK fork tubes with race tech internals, 400f bars and the stock polished LH switch is coming off.

Its getting stock 500/550 bars, two brand new reproduction switches, new cables, retaining the dual disc so getting new longer lines. The cb500K0 inspired me to return to the stock set up - I wanted to facelift this bike but it was just as much about retiring it from being my "Everything" bike and transitioning to a leisure rider. Another deciding factor were the aluminum side covers, i love them a lot and want to utilize them on the right bike which involves me have a mounting system for them that require fab work - and i want it done right. This bike is getting stock survivor side covers, the dent in the tank is getting pulled, I have a survivor set of K0500 fork ears that dont have good chrome so all will be repainted together....the bike will essentially get a paint scheme similar to the 750 k0-k1. Stock fronts triple going back on, stock fork gators, stock fork ears - i might go back to stock fenders if the stock front fender doesnt look too goofy mated to the 18" front wheel.

I'm going to sell off the billet triple tree assembly, motogadget sign, joker clips ons, nissin mc, and shorty cables - none of it my flavor really and im fine with letting the stuff go.

the TNK forks and race tech guts are getting donated to my cb750.

list below updated with stuff coming off or changing.

rebuilt top end base gasket up, new piston rings
billet lower triple - stock top triple - Bike comes with match top billet triple clamp and joker clip ons.
new shorty throttle cables from 4into1
nissin MC
Godffrey dual disc drilled and thinned rotors with phenolic caliper rebuild
Godfrey speedo delete mod
SS brake lines
NOS cb550 seat
new aftermarket starter switch housing
polished oem turn signal switch housing - all switches function as they should
new reproduction switch from 4into1 purchased
stock tachometer - this tach broke and needs to get replaced.
aftermarketsmall chrome or refurbished stock instruments will be used
led headlight - not purchased yet
excel 18" front and rear Winged aluminum rims with Buchanan spokes and nipples
new rear Vesrah brake shoes
new brake fluid
new Castro motorcycle oil (non synthetic)
new o rings at fuel T's on carbs
wire harness replaced 2 seasons ago
new wire harness from everettpowersports purchased
tarozzi front fork brace with modified front fender
LSL fork ears
motogadget rear turn signals
new aftermarket blank side covers
timed, carbs synced, valves adjusted.
NOS finned points and alternator covers
extended side stand
mac 4-1 header, unkown midsection, cycle-X slip on muffler.
frame powder coated 2 seasons ago

[Shtonecb500]

new wire harness, new handle bar and switches, replacement stock forks are  all installed. It's really weird but the stock side brake caliper arm needs to be shimmed...i get shimming the dual disc side but the stock brake side shouldn't need anything at all. Ive got spacers at all three mounting points and they were needed because the caliper arm was binding and not swinging side to side smoothly. With only the caliper arm installed and no calipers you can see how the caliper arm does not sit flush with the rotor. Just weird having so much of an alignment issue on the stock side.

I'll be straightening that out then installing a new MC and see if I can avoid getting new brake lines...Once brakes and MC are squared away the bike will be ready to ride...ill worry about paint later.

[Shtonecb500]

The polished side covers are back on the drawing board and it's because I'm thinking these neodymium 100 plus lb magnets will do the trick. My main concern is going to be heat/cure causing them to be less magnetic...but from reading its only an issue if they are heavily encased in epoxy and these wont be.

I was thinking of applying 6-8 magnets on the inside of the covers with polyurethane heavy duty epoxy for elasticity purposes...so they can stick to the frame rails, maybe even the battery box. Other option would be to epoxy thin steel frame work on the inside of the side cover and mount a few magnets to the frame rails/battery box/electrical tray..ore epoxy some magnets to the backside of the airbox...Or I weld on some very small tabs to the frame rails for points of contacts for the magnets or use the tabs with the magnet since they are counter sunk.....This in combination with some shaping and rubber coating the 3 stock mount pegs will get me the results I'm looking for hopefully. Then the safety wire.

Really excited about this cause I found some chrome headlight buckets for sale that kind completes the entire polished look and this would be easier than a paint job...I know I flip flop

Hope to have this tested out tomorrow.

edit: anyone with experience with epoxy please chime in.

[wolf550]

cant wait to see the results
I should have kept that set that i made without the tabs that were drilled tapped and bolted
maybe a set like that and the magnet would be a screw in option on them

[Shtonecb500]

ok, so I became incredibly frustrated during the mock up of the aluminum covers all just to sell it, so I gave up and stored them. I painted the tank, pair of side covers and headlight bucket gloss black and cleared them....Purchased some alpha6 pinstripe paint and will be painting the decal on the tank instead of using the decals thats I have....those decals now cost damn near 100 bucks and im not using them on this tank, after I paint on the decals Ill clear the tank again, carbs will be rebuilt with new kits.

The only thing remaining is I cant get the dual discs to cooperate, aligned, not dragging, hard turning when handle bars are turned...its been frustrating to say the least.

edit:

Yesterday was bad. I got the tape onto the tank and was ready to paint some lines, went to re adjust the tape and the bottom edge and it pulled the paint off.....it was devastating. Unfortunately, I wasted more time trying to feather those edges and paint those spots that ripped but it was not happening, wasted hours trying that...by the end of the day I dumped paint stripper on it and left it bare, ready for another attempt on a warmer day. The headlight buckets and side covers got some wet sanding and only need another layer of clear so thats a win.

[Shtonecb500]

updating

rattle can paint job in dusty environments...

[seanbarney41]

sooo goood!

[Shtonecb500]

thanks bro.


Painted the tank emblems and some 550 side covers emblems that Ill put on instead.

to finish list: install some stock turn signals, install new rear sprocket and used good condition chain and front sprocket, front brake pressure banjo switch, headlight assembly, bar end mirrors, install new oil pressure switch and tank emblem clips....that will complete the bike.

[Shtonecb500]

The only thing I’m dealing with now is an oil light that won’t go off. Bike is basically complete…I might add an aftermarket tach.


added: bar end mirrors (had to order new collets) installed stock turn signals with shortened stems, new oil pressure switch...25 mile ride today more later and this weekend.

starts great, pulls great, stops well, very quiet. Im happy.

Ill take nicer picture later and delete these.

[grcamna2]

thanks bro.


Painted the tank emblems and some 550 side covers emblems that Ill put on instead.

to finish list: install some stock turn signals, install new rear sprocket and used good condition chain and front sprocket, front brake pressure banjo switch, headlight assembly, bar end mirrors, install new oil pressure switch and tank emblem clips....that will complete the bike.

The CB550 came out nice 
The wheels are outstanding !

[Shtonecb500]

proof it all works.

[grcamna2]

The muffler sounds quiet also 

[Shtonecb500]

the muffler is loud as #$%*, the bike did great on the freeway today...no tach or speedo but i kept up with traffic so at least 70mph.

I have a SS tach and speedo combo small gauges with the correct ratio, they were 120 bucks from common motor collective...not sure if they are any bette than the 90-100 bucks set on ebay...they are in the shop tho so they will probably end up on this bike, bar ends are coming off because i hate them and i purchased some repro stock mirrors which will also allow for installation of some normal good condition grips....considering some 30-50mm risers for it too but the next owner can deal with that.

[wolf550]

bike looks sweet!
its been so long since the move, after getting my bikes out of storage and re working them to function Ill have to relearn how to ride.

[Shtonecb500]

bike looks sweet!
its been so long since the move, after getting my bikes out of storage and re working them to function Ill have to relearn how to ride.

thank you, im sure it will click immediately.

I ordered stock style mirrors and im searching for a stock 500/550 handle bar in nice shape. I messed with the mixture screws and eliminated the TINY bit of studder when roll on and when its probably climbing over what I can only guess to be 6k rpm...its smooth at both now....still got whip of gas out of my tailpipe though.

[Shtonecb500]

thinking about a set of busso pipes for this bike since they cost 850.

[SOHC4 Cafe Racer Fan]

Still looking for a 2nd to my nomination for Bike of the Month:  http://forums.sohc4.net/index.php/topic,180400.0.html

[newday777]

proof it all works.

That does look and it sounds great! 👍(except for the missed shifts    )

[newday777]

Still looking for a 2nd to my nomination for Bike of the Month:  http://forums.sohc4.net/index.php/topic,180400.0.html

Done 2nd.

[Shtonecb500]

Stock fenders and handle bar back on - I put them back on because the fork brace up front was causing stiction and I didnt wanna deal with that anymore, these are the original fenders that came on the bike when i bought it 6 years ago.

[SOHC4 Cafe Racer Fan]

I wish you had posted these in the BOTM voting thread. This is a beautiful bike.

[Shtonecb500]

I wish you had posted these in the BOTM voting thread. This is a beautiful bike.

Thanks for the kind words, ive been changing how the bike looks basically every few days so... ya.

[Shtonecb500]

just paid and submitted everything to BAT.

Here are a few of the shots, I have to resize everything bc of the resolution so im only posting a few.

ZOOM IN, they look good.

[denward17]

Bike looks really good, Good luck with auction...