Topic: CB550 SC Nighthawk 1st Build

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I have been quite busy, and also quite lazy, it took a while to get a seat bracket fabricated, and a bolt unstuck from the engine case.

So once that got done, I was able to finally build up the energy to put the front end on and the motor in, so while I was at it I put the engine cases on, tank, seat, and took a picture.

So tell me what you think.

I'll wrap the pipes either in copper or black wrap after I clean them up.

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More pics, with the pipes wrapped, and the muffler machine finished.

I still have carb, and electrical work to do.

[Gixxerusa]

Good looking bike. Can't wait to see it done.

[bikebitzofvt]

Nice work, thanks for sharing!  That copper really snaps!  Will you do anything to the finish for protection? 

I have a 85 550SC in my shop I'm trying to ressurect for a buddy at work.  It looks like you cut down your mufflers.  Any pointers there?

Keep up the great work!

Tom

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Tom,

Thanks, I'm glad you like it.  I was concerned at first in choosing Copper because I know it can turn green over time if not properly sealed.  The plater assured me it won't turn green, they sealed it with a clearcoat so I'm hopeful it will be alright.

As far as the pipes, can you believe they're stock, I only wrapped the downtubes in black from the exhaust ports to the H-Pipe.  then I took a sanding wire wheel and put a brushed look finish on everything chrome, or stainless, or aluminum, to keep from taking away from the copper.

The front of the bike is copper, the rear is Brushed....didn't plan for it like that but I think it works out.

I visited a friend this weekend in York PA, and found out that J&B Moto (from CAFE Racer TV) has a shop 10 minutes away from where I am.  I stopped by their shop and met Jeff Metz, great guy, nice as can be.  I brought my carbs for them to rebuild and clean, so I can't wait for that.  I also got pics of one of the bikes on the new season, I just can't post them or send them out to anyone as I promised...but it's a typical cafe bike.

I think you'll like the 550, it's got nice power to weight, and if it's DOHC, you should get plenty of good years out of it too.

[popssss]

I added a windshield leather case under the headlight and turned it into the fuse box and ran all the wires into it and such.

I added bar end mirrors and new switches and hand controls too.  I filled the new clutch and brake lines with new DOT 4 fluid and they work great.

I gave each cylinder a shot of WD40 and within a few minutes the engine turned over, even after a year of not being run, so that's a good sign to me.

Next I have to recreate an inner fender and mount some of the electronics to it; stuff that was previously attached to the air box and older side covers.

I think I'll end up doing side number plates at first, and then I may do some shaped pieces.

I used copper plumbing pipe for the rear hoop under the seat, and in these pictures the tail light is crocked, but I since fixed it.

The wiring harness is mostly hooked up, but a few bits and pieces left.

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OK I took some time to hammer out some side over pieces to fill that big empty space where the air box went.

I have the ones from the factory, and fortunately both side pieces were exactly the same basic shape.  The left side was shorter due to the electronics.  I made an inner fender and mounted them all there.

I made the fender go under the seat to hide all the wires too, so it turned out to be a tray..

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Once I got the side pieces made I thought I'd see how they look on the bike.

well the top pictures are pretty bland, and it doesn't quite fit right, I thought I'd get some ideas from the original pieces, so I added a couple of bends into it, and it's much better.

I used some 3/4" square tube and clamps, lined then up against my marks, and pushed it over using body hammers to make the crease a little more defined.  I didn't want them too sharp because it weakens it a bit, so I left the bend a touch soft.

did em all by hand, just by watching all these car and bike shows, I picked up a few tips.

[popssss]

I added number plates to the side covers, I used really thin copper because it was cost effective, and I wasn't sure which way I was going to go with this.

I think long term I'm going to have to use thicker materiel, any suggestions?

I used number 11 because that's the year when I finished working on it.

I could use some ideas on final design.  I put 1/4 inch spacers between the side covers and the number plates.

[grcamna2]

popssss,
     I've been enjoying reading about the work you've done to your CB550SC....I LOVE how the sides of your fuel tank turned out w/ that multi colored shaded copper look on each side coming down to a point near the seat; I think it MAKES the bike w/ lots of depth to those side sections !

[popssss]

Thanks for the reply.

I'm glad it's appealing to other folks too.  I've been thinking of taking it to one of the local bike shows, but my Carbs are still not back from getting cleaned and rebuilt.

I'm having them done at one of the shops on CafeRacer TV, and they've subcontracted out the work to someone else and since Sept I've been patiently waiting.

Once I get them back I'll take it to another shop (locally) to have the carbs re-jetted since I'm removing the stock air box and doing pods.

So I'lll be more comfortable taking it to bike shows when it's running.

[wedoo2]

What are you doing for air intake?  Are the carbs CV units?

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I've got the 4 Stock Kheihin Carbs and will put pod carb cleaners on them.

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I'm finally finished....it took me forever to get the carbs back, and incidentally I didn't use the original carbs here.  I sent them off to one of the companies in the TV Show Cafe Racer...and they outsourced them to a guy named tony, and he said after he finished that he didn't have all the pieces to put them back together. then tells me he saw a set on eBay....so I figure, what is this guy telling me to do, buy those other carbs? well I did, and I'm still waiting for my set to come back from unsaid Cafe Racer bike builder....very frustrating.

So I got this other set of carbs, brought the bike to a shop to synch them, and put them on, all jetted and ready to run...it needed a piece to generate the electrical signal to the coil, I can't remember what it's called, so thank goodness I took it to a shop that could troubleshoot it.  I had to fab up a part for the choke cable to attach to the carbs so it would work....then I fab'dd up a license plate mount to be as far back as possible under the seat but not interfere too much with wheel travel...I needed a new fuse box too, because the little clamps that grip the fuses has a brittle piece that broke.  Ordered one of them off ebay, but it came to me missing one of the internal plates.  thanks goodness I didn't throw the old one away....as I looked at the new fuse box it appears that they removed that one bar, because the tabs were loose, and screwdriver looks to have been wedged in there, so that was frustrating.

I'm had the original clutch assembly machined down so I could use only the choke mechanism, and that turned out great....a few crossed wires and popped fuses later (didn't really know the impact of pos/neg placement of turn signal wires) and now I got a great running bike....hopefully it's a trusty ride.

thanks to the forums for your support and encouragement.

[MoMo]

turned out nice.  Smooth  and powerful ride for a small to medium bike, isn't it?.. good work...Larry

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Thanks Larry,  I'll tell you this old engine is way smoother than all the bikes I've owned, 1986 Suzuki Intruder, 1991 Suzuki Katana 750, 1986 Honda Interceptor, or Suzuki DRZ400S.

No buzzes or vibes in the handlebars or foot pegs.

Makes me really antsy to get my KZ650 project going....in the end I'll likely sell one or both (but only to get a new Triumph, Ducati, or Aprilia)

Dave

[bikebitzofvt]

Wow, that came out nice!

I hope your carbs show up soon!  Maybe time to call the better business beureau???

Where did you have the seat done? 

Do you have any of the stock sissy bar parts left?  I'd be interested in buying the top hoop if you do.

Tom

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I had the seat done by a guy on ebay who outsources to North Korea,,,if you look up CAFE bike seat, you'll find him, but if I do, I'll add it here.

I have the rear inner fender, and sissy bar too, but it's not very tall, only like 6 inches.  I have the handlebars too.

Is this the piece you need?

dave