Honda CB516 Cafe

[Seabeowner]

Nice looking minimalist bike. Is bike an import? A lot of imports are not suitable for restoration to original, but certainly suit the cafe racer style. Not so many projects like this on the UK site, but good to see individual skills/ideas. Is it 1st UK registration? Let us know if all goes ok with a heavily modded import.
If they are TEC shocks on the back they are great for original look, but a bit soft. And I read somewhere that if you remove the front guard then a lower brace across the forks was recommended.

[Mace53]

Its been a while since my last post so I have a few updates.

I've finished rebuilding the engine myself with brand new stainless Allen bolts and seals etc. I found the lower crankcase by far the hardest part. Getting the gear selectors in was tough.





However I stripped an already damaged thread on the lower crankcase on the lower oil cap on the offside of the bike. Given that it appears to be just a drain plug I have slapped some high temp jb weld in there for the time being.



I'm now in the process of building the wiring harness myself. New pamco electronic ignition went on which I got from the good blokes from 4 into 1.





Not long now.





Sent from my E2303 using Tapatalk

[hairygit]

I hate to tell you, but that oil cap is not just for draining, it seals the end of the main oil feed to the main bearings. Chances are once the heat and vibration act on it, that jb weld may let go, as that gallery has full oil flow and pressure running in it. If the plug let's go, you will get covered in very hot oil, and the engine will sieze in seconds. Sorry, but better to know now than find out while riding it.

Sent from my X6pro using Tapatalk

[Mace53]

Ah. The repaired one is on the underside of the bike, and not beneath the points cover where I think you're referring to. That one fortunately went on ok. Does that change it?

Sent from my E2303 using Tapatalk

[hairygit]

I don't have a oilflow diagram to hand right now, but I expect that it is still covering a pressurised oilway, hopefully someone with more recent experience on a 500 will chime in (Trigger?)

[Mace53]

Cheers for the info. Its good to know, as I would rather not have her conk out on me on the road.
The high temp jb weld is rated at  232 degrees c on continuous heat. Given that Homdaman rates this section of the engine at around 60 degrees then hopefully the weld should stand.

Provided it isn't in a pressurised oil canal. I'm hoping someone might know this.

Sent from my E2303 using Tapatalk

[hairygit]

Well the oil can reach over 100 degrees C in hard use, and normal running temp of oil is 80-90.

Sent from my X6pro using Tapatalk

[Seabeowner]

Those caps are a nightmare to remove. Perhaps Trigger has some tips as to how to remove as I butchered a couple even with a hex socket and heat.

[Trigger]

What Hairy is trying to say is : Any bodge will bite you back big time. Any leak is a drop in oil pressure and damage will occur.
To get engine oil bungs out, you need a lot of heat and I use a Metrinch socket that grabs the flat surface of the Hex, not something you would find at Halfords or your local car boot 

[Seabeowner]

Wouldn't want to drive around with JB weld there even if as looks likely it's only under crankcase pressure. But 20mm thread and difficult/expensive to repair.
But just answered my question above.
The hex length on the cap is very short and the ally soft as ^%$t.
But using the chunky old Vessel impact driver which has a 1/2 drive with a good fitting 14mm HEX socket (not 12 point!) just removed two from an old engine reasonably easy. (and one was already chewed.)
But pretty impossible with engine in frame.

[Mace53]

Well all I can say is - balls!

Sent from my E2303 using Tapatalk

[Bryanj]

I waay easier to build it all in the top half and fit the primary shaft afterwards!

[Trigger]

I did also notice that you have cut and ground the top yoke, I would love to do a stress test as you have made it structurally unsafe. That is why anyone doing away with a STD yoke would replace it with a slab yoke.

[Mace53]

Hoping to get her started this week.

Sent from my E2303 using Tapatalk

[petermigreen]

Good luck, hope it goes well.
Peter