Partially Restored 74 CB550

[McCabe-Thiele (Ted)]

Yes it was my old photo showing the parts well spotted - in my defence I did I did say in the text.

This is how mine now looks with the kick start spring in position.

.done at last by Macabe Thiele, on Flickr

[Oddjob]

I have a nasty suspicion that the spring inside the gear has lost it's strength or is broken, compare Teds pic to yours, gear is much farther out. As you've got to replace the circlip anyway I'd advise checking, maybe post a pic so we can see if anything doesn't look right.

[davidcumbria]

Teds gap is great ! Never in doubt  Mine( second photo ) is also pretty good compared to the ones in you tube videos. Like you said in your excellent write up below Ken the large soft spring is principally there to stop the ratchet rattling in the at rest open position and doesn’t significantly move the ratchet inboard - it’s the guide path pushing against the pawl on the ratchet as it rotates that does that. I will in any case put a photo of my pre assembly bits up to show I’m not getting that bit wrong.

http://www.sohc.co.uk/index.php/topic,29348.msg281542.html#msg281542

[Oddjob]

What strikes me as odd David is that on Teds pics you an clearly see the large spring, on yours you can't. Which makes me wonder why

[davidcumbria]

The large spring is in there.here is a photo of the parts for assembly today. Also I thought it would be interesting to have a picture of the end circlip. From the left original, first replacement( in and out about 5 times )and the unused new circlip before I fitted it today. [ Guests cannot view attachments ] [ Guests cannot view attachments ]

[davidcumbria]

I was being naughty and used the original tab washer when refitting starter gear to upper case. A tab snapped off when bending back into place so that was a timely warning. Have ordered a new one (90433283000) from DS but they are saying two weeks back order and I fear it could be worse. Anyone found a suitable off the shelf 6 mm tab washer to replace the oem washer ? I  have looked but can’t find anything….

https://www.cmsnl.com/honda-cb550-k1-four-1975-usa_model466/washer-lock-6-mm_90433283000/

[Oddjob]

Got a few of them lying around. I'll bung one in the post for you David.

Just something nagging me about that big spring, doesn't look right for some reason. Seems to be stretched out. So long as it works ok I suppose it doesn't matter.

Like the idea of the ziplock on the shaft to keep the washer in place, good idea.

[davidcumbria]

Many thanks Ken that washer would be a big help. Part of the enjoyment of a restoration is getting to know your bike better and noodling on how little details work. I’ve never really looked into kickstarts before so I find this and our other discussions very interesting.

In other news I ve had to buy a replacement Mainshaft. There was a ridge on a  gear tooth that caused the gears to stick when rotating freely in neutral and I got the complete assy for £50 off eBay. Not sure if this was caused when the selector fork dropped out or by the gears being slightly misaligned when the cases were closed without  locating the bearing pin. Either way it wasn’t mr Hondas fault but the result of  poor engine building.

The amount of fine metal particles inside was horrendous. At one point the cam chain tensioner had dropped off and was found in the sump by the previous top end only rebuilder. He told me  bottom end was ok but shells were completely shot and bottom end gloopy bits in the casing plugs and end of main oil passageway were like grinding paste. Then he  misfitted the keeper plate for  the selector fork shaft so the gearbox  jammed completely after my first ride. It’s a story of real misadventure but nothing terminal and satisfying to get sorted with the help on here.

[Oddjob]

Just found this trawling the web.

https://www.ebay.co.uk/itm/133766546740?hash=item1f251b8534:g:uvUAAOSwYw9j9nWJ&amdata=enc%3AAQAIAAAAwMMHg%2FBzP172w%2BkSDpT%2FJxAgdT2FrXuG%2BDaJSFG0BPI6pReERbu7xYXHnZA0a3xK1Te5bvFTTbBJrkbmR%2BXD70OHwRF2ExEU9ReG72P31EC6tPB%2FQFy05GWssqeojMX9f%2F0M0UuzVxzrRgm55IGZx343k8N3ZRW5PB2KGRLr4UFt6%2BWVEHe0l%2FFuzRe%2FlqMKfQ801Q6sCabBZnjDilJx9L9%2FUj%2Bc8RfT%2BxG4uBGKjZhn7Vocxy6B7qw1ri6UiIcLsw%3D%3D%7Ctkp%3ABk9SR_TSr7WdYg

Thought you'd like a laugh.

[davidcumbria]

That’s horrible profiteering , add the postage and vat and you’re looking at 60 quid for a washer that cms had on sale for a couple of euros. I hope we can meet up some time so I can shake your hand and buy you a pint.

[davidcumbria]

Replacement used Mainshaft  arrived today. Was pleased to find using new shaft all gears now rolling smoothly over each other. Tracked the slight sticking problem on the original gear down to a couple of teeth. Since it is  wear lines across the width of the teeth( bit hard to make out in the photo bit the speckly white band is a channel dug out of the tooth - the narrow grey band above and below are the same tooth surface and the vertical banding is the end of the tooth)I think this is more likely due to the incorrect assembly with the unseated  bearing location dowels pushing the shafts out of alignment. (And pushing through the casing at the other end when tightened in gorilla mode) Actions have consequences! [ Guests cannot view attachments ]

[davidcumbria]

About to join cases.
Does this look ok? The output shaft oil pump bearing hole is vertical ( pin located) though the photo makes it look otherwise.

[ Guests cannot view attachments ]

[Oddjob]

Where's the starter gear on the primary hub?

[davidcumbria]

Thanks Ken just saw that  I needed to put that on too looking at another rebuild.

[davidcumbria]

Better [ Guests cannot view attachments ]