Joined here shortly after buying this project and thought I should document my progress (i.e. frustrations) somewhere as this has been a fun and challenging project that I plan on selling once completed.
1976 CB550F
Found someone elses project on Craigslist that they gave up on and it seemed like the perfect opportunity to use up what little free time I had and give me an excuse to be in my garage. I’ve ridden/worked on sportbikes/dirtbikes/cars over the years, but this will be the biggest project I’ve undertaken thus far.
Starting state:After unloading 10+ mostly unmarked boxes and a frame I tried to inventory and organize as best as possible, but there are quite a few unidentified pieces that remain and I haven’t even cracked open the engine. Supposedly it needs a new cam, but I have boxes with rockers and pistons and don’t know yet what’s inside and what’s a spare. The previous owner had the engine and carbs vaporblasted as well as the wheels and misc items powdercoated. I’ve spent a lot of time and wire wheels removing powdercoat from areas it shouldn’t be in to make things fit.
Current state:Somewhat of a roller at this point. I’ve had little time to work on this project but every so often I get a spur of motivation and multiple boxes from 4into1 and eBay to keep me going. I’ve assembled, disassembled, and re-assembled this
Goal state:The end goal is a minimalist cafe/brat style bike that I will sell shortly after completing. Considering the state it was in, a restoration was out of the question, and if I put enough time/money/effort into a project I want it to be one of a kind and look the way I’ve always imagined.
What I’ve done so far:Removed surface rust and painted frame
Replaced wheel bearings/seals Front and Rear (twice on the rear)
Upgraded head/stem bearings to sealed
Chopped the rear end (hoop needs welded)
Installed clip-ons, grips and new controls (then reverted to stock controls)
Ran new brake lines and clutch/throttle cables
Rebuilt and installed front brake
Rebuilt 1 carb (every nut and bolt in the carb assembly was removed)
Assembled rear hub/brakes
Laced/trued wheels (wow was that not fun)
Mount/balanced tires
Rebuilt forks
Installed dyna coils
New rear shocks
Installed swingarm bushings
Replaced regulator/rectifier with a new combined unit
Replaced flasher relay for a new LED compatible one
Purchased a lot of new tools
What I need to do (that I can remember):Finish carb rebuild
Decide on jets before finishing carb rebuild (5,280ft elevation, free flow exhaust, velocity stacks or intake box)
Finish running the wiring
Build new electronics tray
Paint (tank, likely a chopped but paint matched front fender)
Engine - Install new cam (stock was in bad shape, ordered a few used to find best condition)
All new gaskets
Install Dyna ignition
Run rear brake controls
Install 4 into 1 exhaust it came with, decide if I like it or not
Install new clutch
Install headlight
Still deciding on:Gauges and indicator lights setup
550/650 cam (whichever I find in the best condition)
Turn signals (possibly bar ends on the front, integrated in the hoop for rear)
Rear brake light
Color for paint
Rearsets
Seat (this one was a freebie)
Gas tank - stock or slightly different
Pods/Stacks/Filter box setup (I know the right answer)
Keep stock headlight or change out
What I’ve learned so far:More than I can recall, mostly thanks to this site
Never buy someone else's project
When it doesn’t fit, stick it in the freezer and get out the heat gun
Label every single nut and bolt you remove