It’s home at last!

[Johnny4428]

Sorry meant to attach picture. Doh!

[Oddjob]

Try long straight HT caps on the inners Johnny and use the clips on the breather cover to hold them in place. You can also use clips for the outers, just position them on the cover bolts.

[Johnny4428]

Try long straight HT caps on the inners Johnny and use the clips on the breather cover to hold them in place. You can also use clips for the outers, just position them on the cover bolts.

I actually tried the longer angled cap on No 2 cylinder and it worked perfect. Need to try No 3 where the tacho drive is.

[Johnny4428]

Decided to have a go at the swingarm bushes today, all came apart without too much hassle. Not the best looking collar but well within spec. Will clean up and degrease all parts and fit new bushes supplied by nurse Julie. Quite pleased to see some grease in there.

[Johnny4428]

I need to replace clutch and throttle cabled on the 550 which I’m calling a K0.5. The year of manufacture suggests it’s a K0 but the numbers suggests it’s a K1 makes no difference to me but one thing I’m going to definately change is the handlebars. The ones on it are horrible. I’m thinking from a 550f as I want to retain the concealed wires from the switches. I notice that you can buy new bars of this type, has anybody tried them?

[Oddjob]

Think Ted has Johhny, can't remember if he said they were drilled for the wires or not.

[McCabe-Thiele (Ted)]

I bought these bars from Bertumsbits - has holes to fit concealed wiring - seem good value etc.

https://www.ebay.co.uk/itm/303327670144

[Johnny4428]

Thanks guys! Nice one Ted thanks for link.

[Johnny4428]

Been for another blast out today, just a 12 mile run. Bit of a fix this time of year. At last she is running good with no hanging idle and no hesitation. Work carried out so far. Stripped and cleaned carbs and fitted new intake rubbers. Cleaned out filter box and fitted new filter (CB500) one, after good advice on here just used the existing box with packing foam in the bottom. Drained oil and new filter, filled with some fresh mineral diesel engine oil. Stripped seized master cylinder fitted with refurb kit. Stripped and painted Caliper and fitted with new seal and pads. New brake shoes fitted in rear wheel. New drive chain. Bit of play in drive side of swingarm so stripped and fitted new bushes, purged old grease out of centre bolt using heat gun, worked a treat. Removed number 4 exhaust and welded three patches to the underneath just to bring the decibels down a touch. New exhausts under the bed, to be fitted later. Also new handlebars ready to go on sometime. Removed coils and fitted new HT leads, new plug caps and new plugs. Strobed ignition to make sure advancer was working, no adjustments required. Vacuum synced the carbs with a little tweaking which made a considerable difference. Drained and refilled forks with new fork oil. So she is good to go whenever I get a dry mild spell. Still probably going to strip the bike, but for now she’s another runner.

[Oddjob]

Nice one Johnny, well done. Any undue noises from the engine?

Not sure when you're going to strip the engine but just to let you know, I looked at another members 550 earlier this year and his clutch basket was loose, the internal rubbers have clearly gone hard IMO, this allowed the large gear on the back to move back and too, to replace these you need to drill the heads off the rivets holding the basket to the gear and that allows you to access the damping rubbers. However finding these rubbers is very hard. I'll be sourcing some in the new year from abroad, they won't sell to the UK so another member on here who lives in Europe has kindly offered to buy them for me and send them on, I'll be replacing some of my clutch baskets rubbers when I get them. If you've tested yours by then and find you need a set let me know and I'll add them to the order. If I've already ordered I'll let you know where they came from and the member who helped me out, I'm pretty sure he'd help out another member if asked nicely.

Replacing these rubbers (if they are gone of course) helps stop the clutch basket banging on tickover and also prolongs the life of the primary chain as it stops that lashing around as much as a result. All worth while for the expense IMO.

[Johnny4428]

Engine is surprisingly quiet Ken. I am reluctant to open it up at all. But at a very minimum I will strip the top end to lap in the valves and renew head gasket and seals. Maybe next winter. But the clutch I would say is the only noisy bit on the bike. I could safely say order me a set Ken because I’m sure I will use on the K1 or as I call it the K0.5, if not required I’ll use on the K3 which weren’t rep,aced when the bike was restored.

[Oddjob]

Ok, I'll add an extra set to the order Johnny, if it works out you don't need it I'm sure someone on the site will or maybe my BIL for my other 500.

[Johnny4428]

Thanks Ken, just PM with payment details when required.

[Johnny4428]

The only place that appeared to be seeping oil was from the clutch cover. So quick search among stash and found a new clutch cover gasket. When I removed the cover it revealed quite quickly why it was leaking oil. No gasket! Just some badly applied gu of some sorts with small bits of the old gasket still stuck to the faces. After you mentioned new clutch basket rubbers yesterday Ken I was keen to check and I can confirm I definately need them. Good clean on the faces and new gasket fitted and good to go again. Worked a treat doing this job with bike on the side stand only lost a very small amount of oil!

[Oddjob]

The 500 does suffer with the hard cush rubbers as well Johnny but for some reason it appears the 550 suffers more, I'll get round to ordering them in the new year sometime.