Doms CB550F1 project

[Oddjob]

The 500/550 is the easiest of the fours to work on, only two "specials" you need
1 rotor puller and an ht bolt with correct thred will work
2 clutch nut peg spanner and you can make one from an old socket and cutting disc

Eh??? The 500/550 doesn't have a clutch nut Bryan, it's a circlip. You're confusing it with the 400 I think.

[DomP]

I've had a look tonight and you're right Ken, there's a spring on the rocker shaft.  What the hell is that all about?!

[Trigger]

Should not have springs on the shafts Dom. Only fitted to the 350 and 400's. Looks like someone got confuse with the manual on the 550/400.  That is why your valve stems are chipped so much and you will have to replace any damaged valves 

[DomP]

Oh crap, seems I've definitely bought a bit of a s####er, I'm a bit far in to give up now though

[Trigger]

The Haynes manual covers both the CB400 and the CB550 in the same book and it looks like the previous owner has taken the information on the CB400 rockers and applied it to a CB550 engine 

On a CB400, if you have the springs on the wrong side of the rockers, you get the same result on valve stem chipping after some time   

[Trigger]

If you look half way down this page on Julies thread on a CB400 you will see the springs on the shafts 


https://www.sohc.co.uk/index.php/topic,14049.30.html

[DomP]

I'll take them off tonight then, looking at the shop manual there's nothing in their place which makes me wonder what takes up the slack?  I've written a list of bits I think I need at this stage-

Cam chain £35, Ken
Primary chain  £48.40, Kawasaki
Primary dampers £6.41 each, DSS
Vesrah full gasket set £94.80, DSS
oil seal set £?
Piston set, Cruizinimage or DSS
Cam chain dampers £10.69, DSS
Valve stem seals £24, DSS
Hondabond £20

Any opinions or additions to on that list so far?

[Trigger]

I'll take them off tonight then, looking at the shop manual there's nothing in their place which makes me wonder what takes up the slack?  I've written a list of bits I think I need at this stage-

Cam chain £35, Ken
Primary chain  £48.40, Kawasaki
Primary dampers £6.41 each, DSS
Vesrah full gasket set £94.80, DSS
oil seal set £?
Piston set, Cruizinimage or DSS
Cam chain dampers £10.69, DSS
Valve stem seals £24, DSS
Hondabond £20

Any opinions or additions to on that list so far?

Valve stem seals come in the gasket set Dom but, the head sealing rubbers (pucks) do not 

Oil pump o'ring kit from julie.

You will not know until you fully assess what you need at the full strip stage but, any short cuts and these engines bit back 

[DomP]

Should I be using plasti gauge on the conrod big ends

[Trigger]

Should I be using plasti gauge on the conrod big ends

Yes, everything needs to be plasti-gauged up to work out all the clearances.
All gear box bearings need to be checked they are running feely and are not worn. The gear change dogs are with in spec and so on 

[Bryanj]

Do you mean cam chain tens blade and cushion as dampers are little things that go in ends of tensioner

[DomP]

Yeah that's what I meant Bryan, the little dampers.

Best order some plasti gauge, what colour?

[Oddjob]

I'll take them off tonight then, looking at the shop manual there's nothing in their place which makes me wonder what takes up the slack?  I've written a list of bits I think I need at this stage-

Cam chain £35, Ken
Primary chain  £48.40, Kawasaki
Primary dampers £6.41 each, DSS
Vesrah full gasket set £94.80, DSS
oil seal set £?
Piston set, Cruizinimage or DSS
Cam chain dampers £10.69, DSS
Valve stem seals £24, DSS
Hondabond £20

Any opinions or additions to on that list so far?

Vesrah kit seems damned expensive, the OE head kit includes valve stem seals BTW and TBH a full kit isn't that attractive. There are only a few gaskets in the bottom end kit and most of the time it's cheaper to buy them separately IF you need them. Rotor one for instance isn't an oil seal gasket, just a seal to keep water etc out. If it's not broken you can reuse that. TBH I've reused lots of gaskets in the past, so long as they come off intact why not. Or buy an OE bottom kit.

I have some of the camchain tensioner damper rubbers somewhere. NOS of course. I'd advise checking the tensioner itself, does the blade compress and expand smoothly, is the release bolt ok, screwdriver slot not deformed or even broken, more than a few are. Is the bottom part straight and damage free, you'd be amazed how many have been caught by the primary chain, the damage is easy to see.

Refrain from buying plastigauge, look at the crank first, assess what needs replacing. It's likely you're going to need new shells, you can order it then if you think you need it.

It's going to get expensive, try and keep the costs down as much as possible whilst buying good parts, you get what you pay for when it comes to engine parts. Most of the roller bearings are available cheaper than OE, same make, same bearing, buy them from Hendersons for example. Same for seals, just chek the old one and you'll see the size printed on it, input that into Google and far cheaper alternatives come up.

[Trigger]

If you just buy a top end gasket set, you will be missing the starter motor cover gasket, the clutch gasket, the alternator gasket, the points cover gasket, sump gasket and all the bottom end o'rings .
If you skimp on using old gaskets, you run the risk of an oil leak 

[Oddjob]

Never changed the starter motor cover gasket, never changed the points cover gasket, almost never changed the oring for the sump.

Rotor gasket isn't oil tight, just water so you can make one if it rips coming off. Only one you might need to change is the clutch cover if that rips, I tend to slide a really thin Stanley knife blade down the gap once all the screws are out, normally got half off without them breaking and you can use them again then.

Orings are dirt cheap and readily available. Same for engine seals, I have most of the orings and quite a few of the seals as I buy them in quantity.

His bill will be high enough without buying parts that aren't always needed. For a few pound more he could source a genuine top and bottom gasket kit and get the right parts, no problem with the head gasket and the orings not sealing with genuine, orings are all the exact size as well. John Oldfield has 2 bottom end kits for £34 each. It's just a matter of searching hard and you can find them at the right prices generally.

If you feel like searching Dom, the part numbers are 06110-390-020 for the topend set and 06111-390-000 for the bottom end set. Have a look around, see if you can find a bargain, they are out there, getting harder to find admitably but still available.