Honda CB550 F2 1977 Supersport Cafe Racer Build

[Bryanj]

When you fit that nice top yoke dont forget the special washers the go on the pinch bolt in the gap to stop you overtightening and snapping the clamp

[Sherlock]

When you fit that nice top yoke dont forget the special washers the go on the pinch bolt in the gap to stop you overtightening and snapping the clamp

Thanks for the tip Bryanj. Are the washers a standard size? If so what? There wasn't one fitted when it was dismantled.


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[Ewan 500 K1]

ooooo- errrrrr , mine doesnt have those washers fitted either. Part number 53235-300-000, looks like a bog standard washer with part of the circumference flattened off

[Sherlock]

http://www.cmsnl.com/honda-cb550f2-super-sport-550-four-1977-england_model17121/partslist/F04.html#results

Doesn't show it on the schematic diagram? 

[Sherlock]

http://forums.sohc4.net/index.php?topic=72765.0

[Ewan 500 K1]

This is a good site for cross refernecing part numbers. The top clamp spacer is no 12 on this schematic:

http://www.motogrid.com/pages/oemparts?aribrand=HOM#/Honda/CB550F_A_(76)_MOTORCYCLE%2c_JPN%2c_VIN%23_CB550F-2000003_TO_CB550F-2010866/HANDLEBAR_%2b_TOP_BRIDGE_%2b_STEM/CB550F-76-JPN-A/2Y133900F13390004A

[Sherlock]

Good & Bad day :-( :-)

Finally removed the engine from the frame :-). Snapped a long bolt in the process and found out these are mega £££'s :-(


Also found out the frame has a hole in it, well, a few... Which are (luckily) on the left pillion bracket so shouldn't have any effect on the frame itself.


Having spoke to someone, it would seem cutting this section out between the frame and the mounting point then welding an identical sized tube in its place would do the trick.

The other problems to address are:

Bolt seized in frame in the front middle engine mounting point.
Rear brake lever spline seized in frame.

Cut rear seat/fender mount off.
Weld new rear end and cross member support bracket


Grind off unwanted brackets etc
Remove centre stand (which appears to be stuck!


I got a quote of £35-50 to shot blast frame and swing arm and £80 to powder coat. Thought that was reasonable. Decided i'm going to get brand new rims as these are rusted to buggery.


So, any suggestions on removing the brake lever spline thingy?


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[matthewmosse]

First choice for me to extract the brake pivot would be heat. Oxy acet is king but butane might do it. Failing that used engine oil, Cheap cola and repeated tapping and soaking in the above will probably sort it. Just don't get too brutal in case you mushroom the end. Twisting is also powerful so tap the leaver end of it. I used the soaking and tapping method on some trailer wheels that were rusted solid onto their hubs when heat wasn't an option because i wanted the tyres.

[Sherlock]

First choice for me to extract the brake pivot would be heat. Oxy acet is king but butane might do it. Failing that used engine oil, Cheap cola and repeated tapping and soaking in the above will probably sort it. Just don't get too brutal in case you mushroom the end. Twisting is also powerful so tap the leaver end of it. I used the soaking and tapping method on some trailer wheels that were rusted solid onto their hubs when heat wasn't an option because i wanted the tyres.

Cheers for this. Didnt think of coke but assume the acidity in it helps break down the rust? Tried propane/blow torch but can't get it hot enough.

[kendo57]

I always use Plusgas and as said heat.
You could drill a small hole into the tube and fill with fluid also, it would be easy to
weld up afterwards or fit a grease nipple.

I ended up buying new rims as well, i wanted tp powdercoat the originals but the powdercoater
said they were too rusty to get a decent finnish.

[Bryanj]

Which bolt was it? If the one that goes all the way through and holds the footrests just buy a length of stainless stud bar and put a nut each end

[z1100r]

Frame looks very rusty. Is it as bad as it looks..

[Sherlock]

Irs been painted by hand by a PO.

Sanded back several areas that look suspect but the frame is okay. Will see more when blasted.

[Sherlock]

Ground some paint off in about 20 places with the dremel tool in the suspect areas and looks okay. It appears to be 3 or 4 layers of paint one being similar to hamerite.











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[Sherlock]

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