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

[DomP]

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

I just have an open topped airbox at the moment Ken but running a 500 filter due to missing so many of the 550 internals.  I'd just like to be able to close it off somehow as I'd imagine it will mess with the carb set up as it is

[davidcumbria]

Good progress Ted. Why did you use copper rather than ss washers on the valve cover ? I would love to see a photo of those bolts you used next to the tappet covers on the front. Your engine paint looks great. I’m  way behind now - haven’t rebuilt my carbs yet. Looking forward to your first start up. 👍

[Laverdaroo]

I've three or four left Dom but go to the states in the morning and back in December. I guess youre not in a rush but just to say Ive a few lurking if you need one.

[Oddjob]

Need to be soft washers on the 6 central bolts David as they seal against oil coming up the bolt. SS would be too hard.

[McCabe-Thiele (Ted)]

Workshop manual or parts book shows the six bolts use copper washers. When I bought the pack I just used the left overs rather than SS. The small ones at the front corners are flange bolts.

[Rozabikes Tim]

Just catching up on this. Lookin good Ted.

[McCabe-Thiele (Ted)]

Good progress Ted. Why did you use copper rather than ss washers on the valve cover ? I would love to see a photo of those bolts you used next to the tappet covers on the front. Your engine paint looks great. I’m  way behind now - haven’t rebuilt my carbs yet. Looking forward to your first start up. 👍

Photo of bolt Dave only fitted them to the two outer front bolt holes where the issues were with fitting the cam caps due to cost.

Cam caps in photo have not been cleaned up as I have some standard replacements - the chromed ones I bought from DS are too bling as well as my concern over the threads.

.cam cover bolt by Macabe Thiele, on Flickr

[McCabe-Thiele (Ted)]

Not sure what specifically did it but I spent some time on the throttle cable adjustments for opening & closing plus altered the angle of the point where the cable unions  connect to the throttle body so that the curves on the cables followed the line better. I did look in Ash's Dropbox but could not find anything that helped me. (probably looked in the wrong places)

ATM the cable routes go from the the throttle, loop down between the forks then follow the frame above the round tank mount (can easily be moved to below the mount above the coils). Photos to follow as I'm going out for lunch & my phone connection is on my PC not the laptop I'm using.

[Johnny4428]

Ted I had mine below the tank mounts on the 550 but they were having a tendency to hook around the lower corner of the fuel tank when manouvering. Definately I would say above the tank mounts can’t drop from there.

[Oddjob]

Those bolts Roo are the 8mm headed ones used on modern Hondas and since the 250N era.

They are the ones I keep advising people to use but everyone ignores me, except my mate Ted of course and Nigel, you know who your friends are after a while 

[Oddjob]

See if this works

[Oddjob]

These might be better





So over the fork top on the top yoke, through the gap in the speedo/tacho bracket, round to the left of the headstock, under/over the tank mount rubber (which is odd as one image shows it above and one below, see which looks right, I suspect below as it would bend the cables less) through the gap in the frame where the coils sit and onto the carb bracket.

[Oddjob]

Just had a thought Ted, make sure the throttle thumb screw ramp in the R/H switchgear isn't wound up too high and is touching the throttle tube. That would make the throttle grab a little.

[McCabe-Thiele (Ted)]

Thanks for the pics Ken, I saw something similar on the PDI pics for the 500. (USA bars I suspect as the throttle cables are above the clocks and feed down through that slot/hole in the bracket)

I tried to route my throttle cables through the hole in the speedo bracket as per the photo.  The cables would somehow have to get past the rev counter with not much of a gap, swooping up from the throttle grip below the bars through a tight gap near the master cylinder pipe then tight down thought the instrument bracket. They were routed better above the master cylinder but ended up part over  the rev counter.

Hence why am now as per these photos.
.throttle route 1 by Macabe Thiele, on Flickr

.throttle route 1 front view by Macabe Thiele, on Flickr

[McCabe-Thiele (Ted)]

Just had a thought Ted, make sure the throttle thumb screw ramp in the R/H switchgear isn't wound up too high and is touching the throttle tube. That would make the throttle grab a little.

One problem at a time Ken I have not fitted the ramp yet but the hole in my switch gear is threaded so will look at that eventually.

I have very loosly tried my clutch cable route - from the bar lever, drops down the slot/apperture in the instrument bracket out on the RHS then through the coil frame hole to the left side  down through the gap between carbs 1 & 2  to the forwards facing hole in the left side housing.

The route looks good except there seems to be excess loops of cable near the tank area - I did wonder if there is a shorter cable for the UK 500 & mine is an aftermarket one. The cable is in good condition - even the rubber bellows at the engine end  looks like new.