Honda-SOHC

SOHC.co.uk Forums => Project Board => Topic started by: AndyH on May 25, 2017, 10:46:22 AM

Title: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on May 25, 2017, 10:46:22 AM
Hi all,

I haven't posted much about my restoration since getting the bike so I guess it's time to provide some info.
I'm in Perth, Western Australia and acquired a CB500K1 which was converted to cafe racer style some 4 or 5 years ago.  The bike was in overall good nick but obviously some things needed to change to bring things back to original.

The duck-tail seat, lo-rise handlebars and mini speedo and tacho needed to be replaced.  Fortunately there were quite a few useful odds and ends that I got with the bike, and a subsequest purchase of a box of bits from another Perth local.  :)

So as it stands now, I have a seat (original base and foam covered with a DSS cover), a new set of RHS and LHS switches (another story... >:( ) , a new handlebar and a bunch of other things like rear footpegs, new headlight and surrounds and a new 2-stay front fender.

I've been cleaning up the wiring loom and connectors, along with some other bits.

A close friend is restoring the instrument faces for me, so they'll be ready before long.  8)

And now to today! 

I removed the “sub-frame” containing the reg, rectifier, blinker relay and solenoid in order to clean things up.
The sub-harness turned out to be an absolute dog’s breakfast….one of the multipin connectors was missing altogether!
Thanks to the CMSNL diagrams I soon figured out that the rectifier module no longer had a multipin connector on it.  Instead, it was sloppily spliced into the sub-harness, with some of the connections just twisted together (no solder) and wrapped with cheap electrical tape. >:(

Once I realised that refurbishment was going to be difficult, I took a heap of photos.  They’ll help with putting things back together, along with the wiring diagrams. 

I tinkered with the idea of getting hold of a replacement harness (which isn’t available anyway!) but then I’d have to source a multi connector for the rectifier.

I’ll strip the paint off the sub-frame tomorrow, respray same then set about putting things back together.  Won’t be too difficult, just not original….oh well!!  ;)

I'll try to remember to take more photos in future.  If you want to see what the bike looked like when I bought it,  here ya go!  8)


Title: Re: CB500K1. Cafe Racer to Original!
Post by: Seabeowner on May 25, 2017, 12:45:50 PM
As you say "cafe racer style" more than out and out cafe racer which can be very difficult to revert. Australian/NZ models are pretty much identical to UK if I remember.
Will you go for original style paintwork on the tank/side panels? And of course the 4-4 exhausts which I presume are actually made nearer to you than me, but do you have a distributor? Or do they have to go China, Holland, UK, Australia.
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on May 25, 2017, 01:18:07 PM
It will be restored in the UK style, as you've correctly surmised.
Original 4 into 4 are unobtainium so I'll stick with the 4 into 1.
I kind of like the tank paintwork so will probably match the side covers with the "candy blue".
I should have said from the outset that reverting to ab-original is an extremely difficult challenge so I'm just going to get it close.
I want to ride the thing, not have it in a display cage LOL!

Title: Re: CB500K1. Cafe Racer to Original!
Post by: toucheturtle on May 25, 2017, 05:37:28 PM
Someone is selling copies of the four in to four exhausts in Australia on ebay but they want crazy money for them

http://www.ebay.co.uk/itm/Honda-CB500-Four-CB550-Four-Mufflers-Exhaust-System-Replica-/182588936538?hash=item2a8326115a:g:QTMAAOSw3gJZJLA9
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on May 26, 2017, 01:39:22 AM
Yes I saw that.  I can purchase a heck of a lot of other bits for that price!  :)

A mate of mine who restores 750s recently priced a set of 4 into 4 from Motorcycle Yamiya......$6000!!!!  ::) ::)
Title: Re: CB500K1. Cafe Racer to Original!
Post by: Seabeowner on May 26, 2017, 09:02:20 AM
In £ terms that 4-4 is about £100 more than UK. DSS and CMSNL must have ordered dozens of sets and have sold quite well here and are usually the key to sale for someone after after an original looking bike. But if it's a bike to keep and ride, then you won't get your money back, but great to stare at when it's parked outside the cafe.
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on May 26, 2017, 10:43:45 AM
My restoration is absolutely not about the money.
Apart from which, I'm retired some 9 yrs now and altho' living a reasonably comfortable lifestyle, I'm not flush with cash!  :(
I want it to look fairly much like it did in '72 and also be able to ride it wherever and whenever! 8)
If I win Lotto however, then the game changes LOL!  ;D ;D ;D
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on August 08, 2017, 09:35:02 AM
Things move slowly in WA (Wait Awhile!)  ;D

Just returned from a trip up into the Pilbara and Kimberley regions of Western Australia.  Now back in the cold hole that is Perth in Winter!!  :-[

Installed the replacement wiring harness, fitted the electrics panel (refurbished & thanks to Cal on sohc4.net for the sub-harness!), rear blinkers fitted/wired and took the front wheel and caliper off in preparation for removing the forks, polishing them and mounting the fork ears.  They've been chromed and ready to go on, but waiting for delivery of top rubber "cushions" from DSS which are now back in stock and should arrive in the next week or so.  8)
Title: Re: CB500K1. Cafe Racer to Original!
Post by: hairygit on August 08, 2017, 09:57:33 AM
Glad to hear things are movie g along. It always makes me chuckle about this forum and the overseas members, I still find it difficult to comprehend that it's winter down under, while we are all moaning it's too bloody hot here!

Sent from my X6pro using Tapatalk

Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on August 08, 2017, 10:13:01 AM
Glad to hear things are movie g along. It always makes me chuckle about this forum and the overseas members, I still find it difficult to comprehend that it's winter down under, while we are all moaning it's too bloody hot here!

Sent from my X6pro using Tapatalk

Well, while we were in the Pilbara and Kimberley, the temps were in the mid 30s....degrees C, that is! ;D
We got within 500kms north of Perth and the temps plummeted.....2°C in the van first thing in the mornings.
It's now 12.6°C outside at home, windy and bloody wet!! >:( >:(  OH well, back to the shed tomorrow to polish up the forks.
 
Title: Re: CB500K1. Cafe Racer to Original!
Post by: hairygit on August 08, 2017, 10:17:37 AM
Sounds ideal where you are now, I hate the heat! 15 degrees and overcast is ideal for me, just perfect, not too hot, not too cold, and I prefer winter to summer. If it's cold you can put a jumper on or light the fire, too hot and you're stuffed!

Sent from my X6pro using Tapatalk

Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on August 08, 2017, 10:19:33 AM
Sounds ideal where you are now, I hate the heat! 15 degrees and overcast is ideal for me, just perfect, not too hot, not too cold, and I prefer winter to summer. If it's cold you can put a jumper on or light the fire, too hot and you're stuffed!

Sent from my X6pro using Tapatalk

No way Jose !  :P  Gimme hot always!!
Title: Re: CB500K1. Cafe Racer to Original!
Post by: Nurse Julie on August 08, 2017, 10:21:19 AM
It's bloody pissing down here and they forecast the same for the next 24 hours. No wonder the farmers have been working 24/7 getting the grain in.....they knew what was coming !!
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on August 08, 2017, 10:24:25 AM
It's the opposite here Julie.  Although Perth has had a lot of rain over the past few weeks, it's not going inland.  The farmers are in for a crook season this year.  The worst for some time.  :-\
Title: Re: CB500K1. Cafe Racer to Original!
Post by: Nurse Julie on August 08, 2017, 10:28:11 AM
Haha, haven't heard the word 'crook' for ages. The other farmers around here that grow all the veggies and salad crops are loving this rain, saves them watering the crops. What's good for one is bad for another I suppose.
Title: Re: CB500K1. Cafe Racer to Original!
Post by: AndyH on August 08, 2017, 11:02:44 AM
Haha, haven't heard the word 'crook' for ages. The other farmers around here that grow all the veggies and salad crops are loving this rain, saves them watering the crops. What's good for one is bad for another I suppose.

Very true.  Meanwhile, I better get my arse into gear and take some photos.........tomorrow!  :P
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 11, 2017, 03:09:38 AM
The 1st two pics show the original sub-harness and electrics panel before refurbishing.

The 3rd pic shows some of the harness wiring, including the crap connection for the electronic ignition.

The last pic shows the bike in its current state, with new wiring harness provisionally fitted, along with several other bits n pieces.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: petermigreen on August 11, 2017, 06:01:27 PM
I just love the whole philosophy of this build  ;D

Thanks for posting.
Peter
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 12, 2017, 08:00:51 AM
I just love the whole philosophy of this build  ;D

Thanks for posting.
Peter

Hey Peter, I must admit my philosophy of the build has been sorely tested at times as I approach every next bit!  I'm torn between leaving things as they are, saying "Nope, need to really tidy this up" or deciding to replace with new....aargh!   At the end of the day tho', as I've said previously, the bike will be a practical "everyday rider" without me having to worry about the fact that a few bits maybe aren't 100% original or pristine.

Nonetheless, having not undertaken a project of this kind before, I'm kinda liking the challenges that it throws up as things progress!  8)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 19, 2017, 08:21:33 AM
Cabling and wiring in place.

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: petermigreen on August 19, 2017, 06:52:52 PM
Looking factory fresh  8)

Nice job.
Peter
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 20, 2017, 11:03:51 AM
Fork ears waiting for top rubbers prior to fitment.  As originally received, they were sandblasted within an inch of their existence!  A fair bit of work was undertaken to make them viable, and then they were chromed.  They're not 100% but trying to get hold of any reasonable replacement is nigh on impossible!  The term "unobtainium" comes to mind!  ::)

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 26, 2017, 01:09:44 PM
I mucked around in my shed today, and rummaged in a parts bin and found some top fork ear rubbers in good condition!  So the ones coming from DSS will go into the "new parts" parts bin.  ;D

I figured "What the hell", and went ahead with the fork ears, gaiters, caliper, front wheel and fender install today!  8)

Need to go to my local auto store tomorrow for some brake fluid, then bleed the brake and wheel the bike out of the shed for the 1st time in 3 months!

Getting ever closer to completion now. 

Last 2 pics show my messy bench, and my mate's "you beaut" meter crimp ring compressor.  ;D
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: hairygit on August 26, 2017, 01:26:08 PM
There's a fair bit of work gone into that ring crimper, does he do enough to make it worthwhile? You're bikes coming along nicely, wish it was winter here right now!

Sent from my X6pro using Tapatalk

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Seabeowner on August 26, 2017, 01:36:11 PM
Looking great Himble. Fork ears look good and like the contrast of the black on the cylinder block. Every plating shop seemed to do chrome in the 70s but regs have curtailed that number and prices high. How about Oz? That is an impressive bit of kit for the meters and your bench ain't messy, I can still see some of the work surface.
Only reason I wish it was winter it get some of the holiday traffic off the roads.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: JamesH on August 26, 2017, 02:32:24 PM
That meter crimp ring tool looks awesome...very jealous. Does the handle operate some kind of ratchet mechanism?
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 27, 2017, 02:46:00 AM
Guys, I can't wait for Winter to be over!  Too darn cold for me!

The crimp ring tool will be getting a lot of use.  My mate is in the process of restoring 10 bikes, and another bloke in the club has at least 10 Hondas in various stages of restoration.  It's designed to handle both sizes of Honda meters.  The handle just moves the "base" around (no ratchet mechanism) but my mate has ideas of incorporating a motor to rotate it.

Phil (Seabeowner),  chrome plating in Aus. is also very expensive, and very few places do it now for the same reasons of  regs.
Lots of folk are cad-plating smaller items though.  My rims are in a fairly poor state, but it would be more economical for me to purchase new rather than get them re-chromed.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 29, 2017, 10:57:37 AM
Fitted the headlight bucket, blinkers and mirrors.  PO didn't use the original fork ears so I had no collets (#13 in the h/light schematic below).  Fortunately I had some tube stock in the shed of the right size so fabbed up a couple.  :)

Getting closer to completion.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on August 29, 2017, 08:31:56 PM
Tank looks great, nice work 👍
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 30, 2017, 06:40:43 AM
Tank looks great, nice work 👍

Thanks Mark.  :) 
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 31, 2017, 11:29:20 AM
Finalised the wiring connections Yesterday.  Fitted the headlight and battery then carried out a couple of continuity checks.
When I turned on the ignition, lo and behold I had the neutral and oil pressure lamps come up!
No nasty burnt insulation smells either.
Tested headlight, park lights, blinkers and rear brake light...all good.
When I bleed the front brake I'll test that brake light.
Have mostly filled the tank, and run a couple of hoses down to a clear bucket to see if I've solved the petcock leak (screws leaking past the fibre washers). 

UPDATE:  No leaking!  So I've decided to change the fuel lines to the carbs....that was a challenge, but thanks to various threads on this forum I was able to do the business without too much drama.  As many have said, this resto business is a case of patience and beers, patience and beers....in my case, patience and red wine!  ;D

Tomorrow I'll refit the tank, connect the (new) fuel lines and press the "Start" button!  ;)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 01, 2017, 09:09:10 AM
We have a heartbeat!  ;D

I mucked about a bit with the clutch cable as I wasn't happy with its routing.  After sorting that out, and fitting the fuel hoses to the tank I carried out a visual inspection to make sure I hadn't forgotten anything.  All good, so I turned the petcock "on" and went back inside for a coffee.  Suitably charged with caffeine ( ;D) I returned to the shed and turned the ignition key on and pressed the start button for just a few seconds to ensure that the starter motor would actually work!  It did, so I pressed the button for a few seconds more and she spluttered into life, then stalled.  I then realised I hadn't applied any choke ( :-[).  After a few more tries, things settled down and I was able to turn the choke off and enjoy a nice idle burble.

Happy?  You betcha!!   ;)  Just need to finalise the tacho and sidecovers, check a few things like carbs for sync etc., confirm correct battery charging.... then time to ride!  :)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on September 01, 2017, 10:31:28 AM
Great moment when they fire up, congrats 👍.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 01, 2017, 11:30:41 AM
Thanks Mark.  :D
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 14, 2017, 09:07:11 AM
While setting up a float bowl swap between #1 and #2 carbs to isolate an annoying leak in #2, I took the LHS crankcase cover off to more easily remove the bowls (clutch cable in the way).

Pleasingly, there's no sign of any oil leaks from the various seals, and the clutch push rod is still in one piece!  8)
I also took the opportunity to give the neutral switch components a clean up, as I was experiencing the odd time when the indicator didn't indicate!

Now to wait to see if the overflow leak problem has swapped to #1 carb, stayed on #2 carb or gone away.  ::)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on September 14, 2017, 08:19:22 PM
It's relatively common for the brass overflow (snorkel) tube to fracture along its length, hairline crack, hard to spot, if it still leaks the chances are that's what it'll be, if you get some black oily dirt on your finger, then rub it around the the tube, then wipe it off again, the dirt thats gotten into the crack will show where it is, if you can't readily get a replacement bowl you can repair the pipe with electrical solder I believe, I was lucky because a forum member kindly gave me a spare bowl when it happened on my CB750.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: petermigreen on September 14, 2017, 09:27:09 PM
Yes, VERY hard to spot, especially with 'old' eyes. As Mark suggests, I fixed the same problem by running a little electrical solder in the split. Fixed it a treat.
Good luck with your fault finding, Carb problems are my most hated thing on motorcycles.
Peter
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 15, 2017, 10:36:41 AM
See  my other thread (http://www.sohc.co.uk/index.php/topic,13879.msg111037.html#new) for the latest.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: hairygit on September 15, 2017, 10:53:13 AM
Also check the condition of the fuel pipes/lines, as modern fuel can attack certain rubber items and be breaking up internally even if they look okay from the outside and don't leak.

Sent from my X6pro using Tapatalk

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on September 15, 2017, 06:36:35 PM
Another possibility is that the number 2 float is too heavy and isn't floating correctly, I had this on one of my carbs,  the float had become porous and was weighed down with fuel, just enough that sometimes it wouldn't push hard enough against the float needle for it to maintain its seal, I noticed when I had the bank of carbs inverted on the bench with the bowls off to check the float heights, one was sitting a couple of mm lower than the other 3, I moved it to the next carb and it sat lower on that one, then I saw a minute pin prick of fuel weeping out of the float, I replaced it with a good second hand one and the issue was fixed.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 16, 2017, 10:20:49 AM
Good points Hairygit and Mark.  :D

Took the bike for a blat this arvo after tweaking the timing on the Dyna S.  Went like a shower of ****!!  8) ;D
Waiting now for the paint job on the side covers to be done.  Tappet check/adjust tomorrow and carb sync a bit further down the track.  Even furtherer down the track, new or cad-plated existing spokes and a cleanup of both rims, hubs etc.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 18, 2017, 09:18:38 AM
I received the replacement (read "correct") tacho from Bryanj today and checked its operation...all good!
Now in the process of refurbishing before mounting it permanently.
Also did a check of the charging circuit.  Voltage at 3000rpm and above was a bit low so tweaked the regulator voltage adjust screw, now seeing ~14.5v as per shop manual.
Waiting now for the paintjob completion on the side covers.
Also received a carb repair kit from cruzinimage_au.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Bryanj on September 18, 2017, 02:19:59 PM
Glad it worked out, got to you on the other side of the world quicker that some stuff inside UK, shame about postage costs!!
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 19, 2017, 11:15:01 AM
In the mail today, received the clips I was needing for the #1 and #4 plug leads that attach to the breather cover bolts.
With the plug connectors I received earlier I completed the stock plug lead routing.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 27, 2017, 11:35:08 AM
My sidecovers should be ready for pickup at the end of this week! ;D
Also have a sync kit on its way.  The leaking carbs (overflow after a day or 3) are still unresolved as #3 dumped today.  :(
Anyway, I'll sync the carbs and at a later date pull the carbs if the o/flow issue with petcock ON still occurs.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 02, 2017, 11:05:01 AM
The carb sync gauges arrived today.  Being relatively cheap I didn't expect "professional" quality and I didn't get it!  :(
The needles at rest were all in different spots so I figured there must be a way to make them all the same.  The "way" was to ease off the front faces of each gauge and "reset" the needles to the proper spot.  This done, I then set up my trusty old vacuum cleaner to provide a pretty constant vacuum for the 5mm hoses.  Fortunately, all 4 gauges read within a gnat's c0ck of each other!  8)  Unexpected roadblocks notwithstanding, I'll do the sync tomorrow.

Long story short, the original side covers are now being replaced with a set from Joe (www.fb-stuff.com) which I ordered over the w/end here, so hopefully will see them in the next couple of weeks.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 05, 2017, 10:32:43 AM
Still wasn't happy with the gauges, so borrowed my mate's Motion Pro Synchroniser to confirm what the gauges were saying.

It was interesting to watch the interaction between the carbs as adjustments were made.  I was able to get all 4 carbs pretty well exactly the same and also confirm that the gauges were close, but not quite as accurate.  I believe this type of comparison has been discussed elsewhere but it's nice to see it in the real world!

I still have this current problem though, if I restart the bike after 15min/30mins/1hr/6hrs etc. it stumbles and farts and sounds like at least one cylinder is not firing properly, if at all  ???.  It's very hard to get running 1st off.
But once it “clears its throat” it idles quite well and seems to accelerate without coughs or splutters.  Blipping the throttle, it comes back to idle without drama.

This lack of normal start has only occurred since I put some Nulon (Aussie stuff) carb cleaner in the tank, hoping at the time it may have cleared the problem with the overflow on #2 carb.  In fact #3 has started o/flowing as well!  :o

I have new hoses from the tank to the carbs, but maybe the small hoses that interconnect 1 to 2, and 3 to 4 have reacted to the carb cleaner and particles from them are now clogging the float needle(s) and maybe the slow jets ……either that or crud that has existed in the carbs before “dosing”.   In any case, a complete carb refurb seems to me to be the best approach now.
Sound like a good idea?

Cheers, Andy (aka Himble)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 05, 2017, 06:47:03 PM
I think a carb strip down and clean/refurb sounds like a good idea Andy, at least it will rule out the carbs as the issue one way or the other, will you be sending them to a specialist or doing them yourself?
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 06, 2017, 01:19:44 AM
I'll do them myself Mark, with the assistance of my mate who has an ultrasonic cleaner.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 06, 2017, 09:48:43 AM
Let me know how you go on, I often have the "starting on three" issue, after about 30 seconds the 4th chimes in, or if I take no4 airfilter off and squirt carb cleaner into the brass balance pipes it starts immediately on 4, so definitely a carb issue, float heights are all good though, never been enough of an issue to warrant a deeper look for me though, but if you find the fix I'll do the same! 😄👍
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 06, 2017, 10:49:56 AM
Let me know how you go on, I often have the "starting on three" issue, after about 30 seconds the 4th chimes in, or if I take no4 airfilter off and squirt carb cleaner into the brass balance pipes it starts immediately on 4, so definitely a carb issue, float heights are all good though, never been enough of an issue to warrant a deeper look for me though, but if you find the fix I'll do the same! 😄👍

No probs mate!  Following a suggestion from a US forum member, I drained all 4 carbs in turn with petcock on (actually an aux tank for synch work!) and found a fair few varnish type (very small) fragments in the capture.

I may be wrong but these bits may be contributing to the issue.  Anyway, I've definitely decided to pull the rack and completely refurbish the carbs.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 09, 2017, 11:57:20 AM
Removed the carbs and deracked them.  Have removed all jets, emulsifiers etc. and given them a good bath in Simple Green in the ultrasonic cleaner.  Amazing how much rubbish is removed with this method.

The emulsifiers were seriously clogged up but all other jets looked OK.   I've completed carbs #1 and #2 and did have to adjust the float levels slightly.  Carbs #3 and #4 tomorrow, then I'll do some further checks on float levels etc., before re-racking.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 10, 2017, 11:09:01 AM
OK, carbs have been removed, de-racked, disassembled, cleaned, refurbished, reassembled, re-racked and now on the bench for some checks before returning to the bike.
All is good….so far!

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 11, 2017, 11:17:34 AM
Carb sync....almost there!  8)

https://youtu.be/ns_NmBi9Hl4
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 11, 2017, 08:56:55 PM
Has the starting on 3 cylinders issue?
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 12, 2017, 03:10:37 AM
Yep, runs perfectly well now Mark.  The carb cleanout/refurb did wonders it seems.  :)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: JamesH on October 12, 2017, 06:05:10 PM
Great work, well done..!!
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 12, 2017, 07:02:57 PM
Good news Andy, I really must get mine sorted properly, trouble is every time I feel like doing the job the weather turns out good so I go for a ride on one of my other bikes instead, still winter is almost here!.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 13, 2017, 01:00:36 AM
Good news Andy, I really must get mine sorted properly, trouble is every time I feel like doing the job the weather turns out good so I go for a ride on one of my other bikes instead, still winter is almost here!.

I can relate to that!  Fortunately we're moving well into Spring here and my restoration is almost complete so rides are gonna happen!  8)   32°C (~90°F) in Perth today!
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 13, 2017, 10:47:19 AM
Great work, well done..!!

Thanks James, I'm quite pleased that I've been able to get this far, not having ever "played" with these SOHCs before.  :)
My career in satellite technology didn't lend itself to getting particularly oily!  But now I'm retired, the sky's the limit ...well sort of!  ;D ;D 8)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 13, 2017, 05:53:46 PM


I can relate to that!  Fortunately we're moving well into Spring here and my restoration is almost complete so rides are gonna happen!  8)   32°C (~90°F) in Perth today!
[/quote]

Typical Aussie bragging about the weather! 😄, tbh I prefer riding in cold weather, when I've ridden in Spain etc it feels like I'm riding into the blast of a giant hairdryer!, that said you don't have to ride on salted roads etc so fair dinkum cobber 😄👍
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 14, 2017, 02:33:20 AM
 ;D ;D

For me the best riding weather is mid 20s Celsius, about  78°F.  In fact, even in mid-Winter here the temp can sometimes be lo to mid 20s.  Plenty of riding times!   8)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 16, 2017, 10:40:26 AM
Sidecovers received from Joe in the US are with the painter today, and will be ready at the end of the week.

With the exception of the side covers, this is how the bike looks now.

 
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Nurse Julie on October 16, 2017, 11:30:41 AM
Looking great, well done you.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 16, 2017, 01:09:24 PM
Thanks Julie!  Not bad for an old fart with no prior restoration skills, even if I do say so meself!!  ;D ;D ;D
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Nurse Julie on October 16, 2017, 01:37:16 PM
Thanks Julie!  Not bad for an old fart with no prior restoration skills, even if I do say so meself!!  ;D ;D ;D
Bonza  ;D ;D ;D
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 17, 2017, 09:40:30 AM
Thanks Julie!  Not bad for an old fart with no prior restoration skills, even if I do say so meself!!  ;D ;D ;D
Bonza  ;D ;D ;D

Goodonya Julie!  8)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Rob62 on October 17, 2017, 08:12:39 PM
Nice job! Looks great 👍
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 18, 2017, 09:45:59 AM
Thanks Rob, will look even better when the side covers are on!
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 30, 2017, 05:38:47 AM
After returning the carbs to the bike and performing a vacuum sync (carbs were very close with the bench sync) this project is now essentially complete!  8)  The bike runs well at all throttle settings and returns to the same 1000rpm idle spot.  At some stage I may contemplate a 4 into 4 exhaust but for the time being I'm happy!  ;D

Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Bryanj on October 30, 2017, 05:49:12 AM
Looks great, glad I could help out and nice to see another one in use
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on October 30, 2017, 05:53:03 AM
Thanks Bryan, and thanks for the support mate!  :)
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: MarkCR750 on October 31, 2017, 05:55:28 PM
Cracking looking bike Andy, the paint scheme makes it look a real classic, erm, which it is of course 😄
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on November 01, 2017, 12:40:02 AM
Thanks Mark!
Title: Rims and tyres
Post by: AndyH on March 10, 2018, 09:44:25 AM
OK, I was going to start a new topic but decided to keep it in this thread.....one of the final tasks on this bike is to refurbish the wheel rims and hubs as they're somewhat grotty! 
I've removed the rear wheel and de-spoked same in the hope of resurrecting the rim but it's pretty badly pitted and there's lots of rust on the inside.  I tried cleaning it up but it still looks crap!
I did some initial research into replacement rims and while doing so, checked the tyre that I took off the rim....it's a 4.00-18 Dunlop K81 TT100.  The tyre itself is in very good condition but is not standard size for a 500. I then checked the front tyre and it's a K81 TT100 but 100/90-19!  According to the general specs for a 500K1 the tyres should be 3.25 and 3.5 respectively F and R.

Back to the rim search and I've found that Motorcycle Yamiya sell a D.I.D rim kit (F and R) for the 750s at a competitive price, even when adding on the exorbitant freight costs.  I'd rather buy from them than cheaper rims from Thailand.  If someone knows where I can get D.I.D rims or equivalent at less than $330 (AUD) shipped to my door then please let me know!!  (Re-chroming the current rims would cost me more than this!).
Finally, should there be any dramas in fitting the tyres that I have on 750 rims (assuming that the current rims are std 500 jobs)? 
TIA
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on August 28, 2018, 08:41:59 AM
It's been a few months since I last posted, so....

I procured a set of new D.I.D rims, and after a bit of a drama with a set of new spokes (didn't fit the hubs correctly) I had the original spokes cleaned up and Cad-plated.  After re-spoking F and R hubs/rims I refitted the existing tyres.
I also changed several oil seals (inc. clutch pushrod and gear lever shaft seals).

I recently joined the Western Australian chapter of the VJMC and as luck would have it, last Sunday was a beautiful clear sunny day for a scheduled ride.  I originally thought to take the Suzuki GS750E but decided instead to give the little Honda a run!  180kms was the total distance covered, and the Honda performed faultlessly!

Unfortunately, all good things must come to an end and the Honda will soon be up for sale.
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: Seabeowner on August 28, 2018, 09:41:35 AM
Unfortunately, all good things must come to an end and the Honda will soon be up for sale.
Shame, it looks great and is a versatile bike. Get rid of one of the BMs
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: petermigreen on August 28, 2018, 10:00:07 AM
You’ll regret it....


Sent from my iPhone using Tapatalk
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: philward on August 28, 2018, 10:13:31 PM
Sidecovers received from Joe in the US are with the painter today, and will be ready at the end of the week.

With the exception of the side covers, this is how the bike looks now.
Looks great Andy
Title: Re: CB500K1. Cafe Racer to Original...sort of!
Post by: AndyH on September 18, 2018, 11:45:18 AM
OK so I mentioned elsewhere that I was going to sell the little Honda.....several months on and it's still with me!   I'm struggling to move it on, so I've decided "Bugger it, it's staying!".  Well, at least for now.
I belong to a couple of clubs here in Perth so when a club ride comes up, I can can take the bike that I'm not working on!!
For those that don't know, my NON-Honda is a '78 Suzuki GS750E.
Life is good!  8)
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