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

[McCabe-Thiele (Ted)]

Why, just use a little thread lock.

My thread lock could not be found so used what was to hand.👍👍👍

[McCabe-Thiele (Ted)]

Carbs now fitted & air filter housing in place.
Fitted small gromett to air filter lid  so it holds onto the bolt head at the front.

.airbox fitted by Macabe Thiele, on Flickr


.carbs back on by Macabe Thiele, on Flickr

[Laverdaroo]

coming on Ted, she looks great!

[Oddjob]

No fuse holder Ted?

Missing the black plastic cover off the kickstart lever. Keeps the crap out of the knuckle joint. Seem to recall someone making them and selling them on Ebay. https://www.ebay.co.uk/itm/143595737695?hash=item216ef9125f:g:ZOQAAOSw3axerz5U&amdata=enc%3AAQAIAAAAwLuy3C3OQhU4zlKnwPJLWjEOmwDTqoW1C5kHiSHqlK85R9s%2F5Q6TMEOfXlqcNbqJJsd7ra2JWQx4GyVXOhS5%2Bk9W3%2FFJOy419uId7Ul%2BEjAusA%2FC%2Fm78u6CDjZqKs0nfY954LwyCiRg%2FQPaQHRBhuXuzTdscUV%2F2BO%2Bz7AgJmZutQsZX0n%2Fsx8aMgGi89k7gTVzQpkPuST7waq%2BRreNqsCqPFaEnmpbNpI%2B6a5d82EqUPIJ%2BYpjj09AlH8SdA2UUcg%3D%3D%7Ctkp%3ABk9SR9Dw4ZLsYg

Be careful using domed nuts on the intake manifolds, I've found that unless they are really deep ones there is a chance the nut bottoms out on the bolt, you think it's tightened up so you stop, then you find it isn't tight and it's allowing air to be pulled in past the oring.

Something like these are better. I use those on the exhaust studs as well, keeps the thread from rusting and you struggling to remove them afterwards.

https://www.ebay.co.uk/itm/295955048209?hash=item44e84ba711:g:XTMAAOSwZ5llFtdk&amdata=enc%3AAQAIAAAA0Cteh8SGnUw1Cx5gGQNUNWk%2Fejj9ygmWcb8sM%2BhHl0q6dxR6LxnzIdhQmbm51gnqCo1%2FHHZ0GzUsS04C%2B8dIhZ34JXoy4Q9ylIvKkGC2s69LhsmX4ZDDMCUZcyX5jKJMOUVTnMRGxF3m%2B9uKL3JLDnxsAVdhxZib3GaqcA6JIHbbib1Mod1rT%2BmUFDXckfd%2FUIlBrXbmdQlVJkX7D9r2p2GmTHHvC0xL1cIpssi6T%2B8tRrmIi8YMZferhjonCygZpot%2FOBVxUJ8Yrv6p5Zio5j8%3D%7Ctkp%3ABk9SR5qKx5LsYg

Not supposed to be a grommet on the tooltray Ted although I suspect you know that. It doesn't rattle in use so it's not really needed TBH.

The HT cap shown is wrong for that location, that's for 2 & 3 cylinders, the outer ones use a long right angled one.

Coming on, starting to look the part. I suspect the breather cover is off a 550 BTW, the vent pipe outlet comes out on the other side to the 500 one IIRC.

Pay attention to the way the bolt fits for the rear brake lever adjusting bolt, can't remember offhand which way it fits, bolt head down or up but it's one you can't change over without removing stuff so it's better to get it right before fitting the brake lever. The workshop manual shows it bolt head up but there is a pic in there I'm convinced shows it bolt head down. I'd fit it bolt head up myself.

NOT criticisms, just comments you may or may not find useful.

[Oddjob]

Just remembered this thread on the USA site, it's a 550K but almost the same as the 500.

On post 1 he does something I didn't think was possible and answers your "Am I stupid ?" thread question.

Have a look, you may find his very detailed thread of use to you as well.

http://forums.sohc4.net/index.php/topic,86697.100.html

[DomP]

If you are looking to sell the airbox cover to replce with a 500 one Ted I be interested in yours.  Mine is missing

[Oddjob]

Ted has a 500 Dom, the 550F doesn't have a tooltray due to the snorkel that was fitted to that model.

You need a tooltray Dom? Roo has a couple but I doubt they are cheap as they are as rare as hell. Most have the wire mesh rusted to hell as well so you need to replace that with some stainless steel stuff like Ted has

[McCabe-Thiele (Ted)]

No fuse holder Ted?

Missing the black plastic cover off the kickstart lever. Keeps the crap out of the knuckle joint. Seem to recall someone making them and selling them on Ebay. https://www.ebay.co.uk/itm/143595737695?hash=item216ef9125f:g:ZOQAAOSw3axerz5U&amdata=enc%3AAQAIAAAAwLuy3C3OQhU4zlKnwPJLWjEOmwDTqoW1C5kHiSHqlK85R9s%2F5Q6TMEOfXlqcNbqJJsd7ra2JWQx4GyVXOhS5%2Bk9W3%2FFJOy419uId7Ul%2BEjAusA%2FC%2Fm78u6CDjZqKs0nfY954LwyCiRg%2FQPaQHRBhuXuzTdscUV%2F2BO%2Bz7AgJmZutQsZX0n%2Fsx8aMgGi89k7gTVzQpkPuST7waq%2BRreNqsCqPFaEnmpbNpI%2B6a5d82EqUPIJ%2BYpjj09AlH8SdA2UUcg%3D%3D%7Ctkp%3ABk9SR9Dw4ZLsYg

Be careful using domed nuts on the intake manifolds, I've found that unless they are really deep ones there is a chance the nut bottoms out on the bolt, you think it's tightened up so you stop, then you find it isn't tight and it's allowing air to be pulled in past the oring.

Something like these are better. I use those on the exhaust studs as well, keeps the thread from rusting and you struggling to remove them afterwards.

https://www.ebay.co.uk/itm/295955048209?hash=item44e84ba711:g:XTMAAOSwZ5llFtdk&amdata=enc%3AAQAIAAAA0Cteh8SGnUw1Cx5gGQNUNWk%2Fejj9ygmWcb8sM%2BhHl0q6dxR6LxnzIdhQmbm51gnqCo1%2FHHZ0GzUsS04C%2B8dIhZ34JXoy4Q9ylIvKkGC2s69LhsmX4ZDDMCUZcyX5jKJMOUVTnMRGxF3m%2B9uKL3JLDnxsAVdhxZib3GaqcA6JIHbbib1Mod1rT%2BmUFDXckfd%2FUIlBrXbmdQlVJkX7D9r2p2GmTHHvC0xL1cIpssi6T%2B8tRrmIi8YMZferhjonCygZpot%2FOBVxUJ8Yrv6p5Zio5j8%3D%7Ctkp%3ABk9SR5qKx5LsYg

Not supposed to be a grommet on the tooltray Ted although I suspect you know that. It doesn't rattle in use so it's not really needed TBH.

The HT cap shown is wrong for that location, that's for 2 & 3 cylinders, the outer ones use a long right angled one.

Coming on, starting to look the part. I suspect the breather cover is off a 550 BTW, the vent pipe outlet comes out on the other side to the 500 one IIRC.

Pay attention to the way the bolt fits for the rear brake lever adjusting bolt, can't remember offhand which way it fits, bolt head down or up but it's one you can't change over without removing stuff so it's better to get it right before fitting the brake lever. The workshop manual shows it bolt head up but there is a pic in there I'm convinced shows it bolt head down. I'd fit it bolt head up myself.

NOT criticisms, just comments you may or may not find useful.

Thanks for the feedback Ken it is very helpful.

I expected some comments on my excessive use of copper washers on the cam cover.
My temporary fuse holder was on the live side - now removed - what fuse holder do you mean?
The domed manifold nuts were fitted by Bryan and are a tall domed type.
Plug caps - my bad just wanted the overlong wires out of the way.
I fitted the grommet to hold down the front of the tray as it tends to stand up on the left side with no seat in place.
I'll see if one of my rubber blanking grommets fits the kick start - I might even have one from a 400 lever I had.

Sorry in advance Ash for the SS Hex Head side cover bolts - fitted by PO.

[Bryanj]

Not me Ted, man who built engine was mad on stainless dome nuts for some reason, as you probably noticed

[McCabe-Thiele (Ted)]

I have fitted the new throttle cables this afternoon - throttle return is okay but feels a little bit three penny bit on the return when you let go of the throttle completely. Action feels like a sort of spiral binding.
Should I have lubricated the new cables first?

My cable routing might be questionable as they pass through the forks.

Nice reduced amount of throttle rotation needed for full throttle as a result of fitting the throttle tube that Ken told me about. (CB1300)

[Bryanj]

No lube on Honda cables Ted, ruins the sleeving and coating.
Routing is very important, should be something on Ashs dropbox, pdi i think that shows route

[Oddjob]

You can use silicon oil to lube the cable inners Ted, only silicon oil though. Check to see if they are aftermarket ones, the genuine have a teflon sleeve over the braided inner cable, aftermarket tend not to. Routing is VITAL on those and the clutch able. Check 550 appendum as there is a routing guide in that..

Fuse holder goes in the little slot in the tooltray, it holds 3 spare fuses which is vital for the 500 as it only has a single fuse and if it blows everything dies, and I mean everything. You're pushing it home if the fuse blows and you don't have a replacement handy. Very hard to find, even I have only one.

One of these.

https://www.cmsnl.com/honda-cb500k1-four-england_model14660/case-fuse_38205323000/

Quite rare, Graham had some made a few years ago, no idea where he got them done. Maybe 3D printed?

The tooltray must be bent if it sits up at the front, it shouldn't. Maybe a little heat and some persuasion is needed.

[McCabe-Thiele (Ted)]

No lube on Honda cables Ted, ruins the sleeving and coating.
Routing is very important, should be something on Ashs dropbox, pdi i think that shows route

Thanks I will take a look.

[Johnny4428]

Ted, that bike is coming along nicely, some nice work done there. Looking forward to start up!

[McCabe-Thiele (Ted)]

Ted, that bike is coming along nicely, some nice work done there. Looking forward to start up!

Thanks Johnny nice to get some positive strokes - that said I also take on board comments that point out things thate are wrong or missing.

When my 500 is done I have decided before thinking about another proect to re-visit my 400 as there are some things I can now do better.