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Topics - Charlie J

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Misc / Open / Motorcycle ergonomics
« on: February 04, 2022, 08:20:33 PM »
Just found a great website that simulates riding positions for various bikes relative to rider height. Unfortunately, it doesn’t take girth into account !!

https://cycle-ergo.com

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Recommended Sources for Parts and Services / Rear brake drum relining
« on: December 05, 2021, 03:16:19 PM »
I had a problem with a cracked rear brake drum lining on my CB500 K1 causing pulsing through the brake lever. I tried a number of machine shops asking if the could machine out the old liner and refit a new one using a car brake drum as a blank. Nobody seemed interested in the job either because it was a one off or because it wasn’t something they had done before. I even tried a couple of “Motorcycle Restoration Specialists” who told me the job couldn’t be done and I would have to get a replacement hub. Eventually, I came across a guy called Dave Baker who was extremely helpful and happy to take on the job. I provided him with a car brake drum from GSF Car Parts (part no 600VG0040) that cost £16.29 incl delivery. Dave charged me £60 for machining out the old liner, and cutting the new brake drum for a shrink fit.
I’ve attached a few photos of the process and showing the new liner after fitting. If anyone find themselves in the same situation as me and struggles to find someone to do the job, I can recommend Dave. He is based in Ammanford in west Wales 07463 550559

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CB500/550 / Air box etc
« on: March 18, 2021, 07:50:16 PM »
Could anyone please tell me if these air box/filter parts for a CB550 listed on EBay will fit a CB500 K1! Some of the parts numbers differ for the two bikes but I was wondering if perhaps they could be made to fit without to much effort.

My project bike was fitted with pod filters and from what I have read from most of the experts on the forum, these bikes don’t like pod filters!

The cost of new air box/filter parts are crazy and they seem to be unavailable anyway. After months of checking EBay, this is the first near complete set of bits I have come across.


4
CB500/550 / Alternator phase wire broken
« on: February 18, 2021, 04:24:49 PM »
Having rebuilt the engine/gearbox and refitted it to the freshly painted frame, I’m now starting on the electrical system which is generally in poor condition or missing altogether. As can be seen in the photo, one of the 3 yellow phase wires is broken. Can anyone tell me please if I can just unwind the binding where the white paper pointer is, then locate the end of the broken wire and solder the two pieces together and then redo the binding holding the phase wires in place?

Thanks in advance
Charlie

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CB500/550 / CB500 K1 Front wheel
« on: December 31, 2020, 01:12:53 PM »
Hi

Just about to order some new rims and spokes for my 550/K1 when I noticed a problem with the front wheel. According to the parts book, the front wheel should be 19 ins with 40 spokes. However, the one fitted to my bike is 18 ins with 36 spokes. I don’t know what to order now. Anybody got any ideas?

Thanks
Charlie

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Project Board / CB500 K1 Rebuild
« on: August 10, 2020, 08:44:27 PM »
Just getting started on rebuilding my project Honda Four which I introduced in the new members section. The confusing Subject title is due to the fact that I don't as yet know quite what I've got. The crankcase is stamped CB500 whilst the cylinder block has 544cc stamped on it. I thought from info from David Silver spares that it was a K2 but BryanJ tells me we didn't get a K2 in the UK and it might be a K1.

Anyway, it is what it is and I'll see what I can make of it. First job was to see if I could get the engine running after the bike had been left in a shed for at least 30 years.
So jobs done so far;

Stripped and rebuilt carbs which as you would expect were completely gummed up. New needle, jets, gasket, airscrew etc. The biggest problem was trying to fit the non-shaped o-rings. I had to resort to the use of super glue in the corners to get them to stay in place

New plugs, point and condensers

New oil and filter

Static timing set

Valve clearances adjusted

Timing chain adjusted

Rigged up basic ignition and starter circuit wiring (a lot of the original wiring is missing/damaged

Rigged up temporary fuel supply

Connected to booster start battery charger

Hit my makeshift starter button

The bike fired up immediately  ;D ;D I almost danced a jig. What a wonderful feeling, but it didn't last long. The bike dumped half her oil on the floor, used 2 pints of petrol in 10 seconds and filled my shed and the surrounding neighbourhood with exhaust smoke.

Back to the drawing board. Traced the oil leak to the bolt inside one of the side covers on the cylinder head cover and got that sorted. The disappearing petrol was coming out of the overflow of all four carbs. When I rebuilt the carbs, I set the float height to the specified value of 22mm which just didn't work, I ended up with a height of 26mm using the clear tube method. Fired her up again on the button and the bike is running well but with clouds of grey exhaust smoke. Checked the cylinder compression and it's about 135 psi on all 4 cylinders which I hope is good enough. Next job is to change the valve stem oil seals whilst leaving the head on to see if that sorts the smoke problem.







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New Member Introductions / New member saying Hi
« on: August 05, 2020, 08:03:04 PM »
Hi all
I've been lurking for a couple days and thought it was time I introduced myself and my new project. It's a 74 CB 500 K2 which looks far better in the photographs than it does in reality. There are quite a few missing or non standard parts and the wiring is a mess. Looking on the bright side it's not seized and seems to have decent compression. I'm not sure what I'm going to do in terms of restoration. I'd like to get it back as close to original as possible but think the cost might be too high for me. The first thing will be to try and get the engine running and then I'll take it from there.

I've already found some fantastic information and guidance on this forum which I am sure will help me along the way. I'll let you know how I get on.

Charlie J

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