Teds new project a CB500 K1 mostly version 0.5 circa 1972.

[McCabe-Thiele (Ted)]

I removed the left side top silencer, loosened the clamps on number two front pipe to find a nice stress free position. Lightly nipped up the clamp on number two port.
I removed the bracket from the upper silencer then re-fitted it as previously. When re-attaching the bracket I could see that the top slot needed a little opening up at the top of the slot to allow the upper exhaust to drop down a tad. A small amount seems to make a difference at the tail pipe end. It all went together well except when clamping the hanger bracket it wanted to pull out of the balancer joint. The Delkevic top bracket has a half circle reinforcing plate attached to the bracket. If I fully tighten the hangar bolt it starts to tip the rear of the silencer.

I'm chewing over the options - might try and fit a sawn in half washer to keep it all flat at the same angle .

Update Just used a slightly thicker stainless washer that has a slight dished shape, fully tightened the nut on the bracket all stayed in place.

[Johnny4428]

Ted that all sounds exhausting! (somebody had to do it). Sounds like you’ve done a good job there bike is starting to look like it’s about ready to roll. It’s a shame when parts are made for a specific model that they don’t fit correctly, especially going to the expense and trouble to produce a quality replacement.😡

[Nurse Julie]

That's strange that the fitting was awkward Ted. We fitted a set of the Delkevic 2 weeks ago to a customer's bike and they fell on with no problem at all. The chaps on the USA forum that have bought them also had no issues fitting them. As with all 4 into 4 systems though, even OEM, they never just fall into place without a little bit of a jiggle.

[McCabe-Thiele (Ted)]

I have a theory Julie that the issue on the left side upper exhaust might have been related to the rear foot peg bracket end angled section just looking very slightly different on the bolt hole end section from the right side. I suspected wrongly that the right side was slightly mis-shapen due to the previous 4:1 system fitting.

The one on the right side that fitted perfectly had a distinctive angle at the tip, the left side hanger was not a mirror image - it was visually slightly different a smoother curve.

One advantage for me was by fitting the bracket to the upper exhaust in situ with the balancer pipe connected I could see where the bolt need to align with the bracket when I slipped it in place. This meant I only needed to file it once as I could see where the slotted hole needed fettling. I did not need to elongate the angled slot just take a small amount of metal from the middle top of the slot.

[McCabe-Thiele (Ted)]

Initially I plan to retain the standard points system then change over to electronic ignition if the bike  runs ok again.

It must have taken me an hour of checking the points gap, checking the F mark for the bulb to light up in the hope that my static timing is good enough on 1/4 & 2/3 can't believe how rusty I am at setting points. I will use my strobe when it's running.

It would be great if the two small pegs for opening the points with a screwdriver were even close to the recess on the other side of the contact breaker.
Presumably I could move the backing section to achieve this. I assume  some of this is linked to the brand of ponts fitted as well. There is no pitting on the contacts they look very new in terms of use.

.500 ponts plate by Macabe Thiele, on Flickr