Topic: Engine rebuild

[Luythen]

Hey all

Im fanally getting a bit of time to work on the old 500/550

i recently bought a used set of pistons and a cylinder for making it a 550 motor.
it needs a ned cam chain tensioner.

what would I need to restore besides fitting the tensioner, and the new cylinder?
Should i open the whole thing and put in a new cam chain+primary chain, new oil seals (the old ones does not leak) new bearings.

Just how far should i go? the engine runs ok one cylinder misfires, (think it's due to a valve not aligning correctly) i have a new head for it.

I would of course like to keep it simple and cheap, but then again, i dont want to take the engine apart more than i have to.

so far the list for a complete rebuild job is as follows

1 cam chain + tensioner
2 primary chain
3 crank bearing shells (no idea how many or wich)
4 complete oil seal set
5 complete bearing set
6 honing and leveling of cylinder
7 valve grinding
8 bead blast
9 paintjob (all black w. stainless screws)
10 complete gasket kit

As you can see this is no small job, but won't it be nessesary when going from 500 to 550?

other things i plan on doing to the beast is

new ignition w. platins
new coils (from a gl 1000)
pods
new custom seat 8making it myself)
new bushings for the swingarm
tapered bearing for the front suspension
paintjob


Probably a bit messy post, but I hope to make a bit of sense

regards

[cbfreaky750]

you pretty much have it in a nutshell 500 to a 550 is about nothing in size the extra power wont make much differnece to that motor one thing i can think of is clutch plates and springs also check the transmission for wear and all valves and valve guides for wear and do new valve seals

CHad

[Luythen]

Well thats more or less the answer i was hoping for :-)

so if the engine runs ok, and the primary anc cam chains are within tolerances I can just leave it in?

the valve guides are ok, i checked them 1000 km ago when i fixed the head gasket. The clutch is ok, the cable however made the whole thing very hard to operate.

I think the block will have to come apart anyway since i have to bead blast the whole thing before painting it, then I should learn if I have to put in new parts or if I can use the old ones.

[Noel]

Sorry to interrupt with a really stupid question, but...

I'm gathering parts for a top end rebuild, and I'm not sure how many piston pin circlips I need. Is there one clip per pin (total of four) or one clip on each end of the pin (total of eight)?

At the moment I have pistons and rings. I think I only need to order pins and circlips to be in business. Is that right?

[siter81]

Correct me someone if i am wrong.But i think there are two circlips for each wrist pin.My k5 750 parts book shows two per pin.

[Bob Wessner]

Yup, two per.

[Noel]

Good to know. Thanks!